Risk reports for product quality planning and management

ABSTRACT

A method to facilitate a Product Quality Planning and Management (PQPM) project associated with a product development cycle is provided. The method includes displaying on a user interface one or more activities to be executed for the PQPM project. The method further includes receiving, with an aid of the user interface, textual inputs indicative of a measurement criterion associated with an execution status the one or more activities. The method further includes developing a report to monitor a risk associated with the PQPM project, the report is based on the measurement criterion associated with the execution status of the one or more activities.

RELATED APPLICATIONS

This application is based upon and claims the benefit of priority fromU.S. Provisional Applications No. 61/470744 by Jason Wayne Flanagan etal., filed Apr. 1, 2011, and U.S. Provisional Application No. 61/470715by Jasmeen K. Harsh et al., filed Apr. 1, 2011, the contents of whichare expressly incorporated herein by reference.

TECHNICAL FIELD

The present disclosure generally relates to Product Quality Planning andManagement (PQPM) and more particularly to use of reports for riskmitigation in the PQPM projects.

BACKGROUND

Organizations depend largely on their products and their manufacturingmethods. It is very important to continuously monitor the manufacturingprocess and in turn the complete product development lifecycle to ensurethat the quality standards and cost expectations are met efficiently.Any lack in quality standards and cost expectations may result in hugelosses to the organization.

Generally, the organizations utilize various Product Quality Planningand Management (PQPM) processes to ensure that every part within theentire product meet the desired quality standards and cost expectations.There may be a plurality of activities and sub-activities to be executedby a team member to successfully complete the PQPM process. Theseactivities and sub-activities may be tracked to monitor the progress ofthe PQPM process. However, the organizations use manual methods formonitoring the PQPM processes. These manual methods involve usage ofvarious forms of excel spreadsheets. However, these manual methods proveto be very cumbersome, time consuming and are highly prone to humanerrors. Moreover, in some instances, manually monitoring the progress ofthe PQPM process, tracking the progress of activities and sub-activitiesor evaluating the success of the PQPM process may be difficult andchallenging.

Therefore, there is a need for an automated system and method forperforming the PQPM process and enabling a team member to monitor andtrack the progress of the PQPM process.

SUMMARY OF THE DISCLOSURE

In an aspect of the present disclosure, a computer-implemented method isprovided to facilitate a Product Quality Planning and Management (PQPM)project associated with a product development cycle. The method includesdisplaying on the user interface one or more activities to be executedfor the PQPM project. The method further includes receiving, with an aidof the user interface, textual inputs indicative of a measurementcriterion associated with an execution status the one or moreactivities. The method further includes developing a report to monitor arisk associated with the PQPM project, the report is based on themeasurement criterion associated with the execution status of the one ormore activities.

In another aspect of the present disclosure, a system is provided thatincludes a processor for facilitating a PQPM project associated with theproduct development cycle. The system also includes a tangible,non-transitory memory configured to communicate with the processor, thetangible, non-transitory memory having instructions stored thereon that,in response to execution by the processor. The processor furtherperforms the operation of displaying on the user interface one or moreactivities to be executed for the PQPM project. The processor furtherperforms the operation of receiving, with an aid of the user interface,textual inputs indicative of a measurement criterion associated with anexecution status the one or more activities. The processor furtherperforms the operation of developing a report to monitor a riskassociated with the PQPM project, the report is based on the measurementcriterion associated with the execution status of the one or moreactivities.

In yet another aspect of the present disclosure, an article ofmanufacture is provided that include a non-transitory, tangible computerreadable medium having instructions stored thereon that, in response toexecution by a computer-based system for facilitating the PQPM projectassociated with the product development cycle. The computer-based systemis further configured to perform operation of displaying on the userinterface one or more activities to be executed for the PQPM project.The computer-based system is further configured to perform operation ofreceiving, with an aid of the user interface, textual inputs indicativeof a measurement criterion associated with an execution status the oneor more activities. The computer-based system is further configured toperform operation of developing a report to monitor a risk associatedwith the PQPM project, the report is based on the measurement criterionassociated with the execution status of the one or more activities.

Other features and aspects of this disclosure will be apparent from thefollowing description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an overview of an exemplary environment in which a GraphicalUser Interface (GUI) module to facilitate a Product Quality Planning andManagement (PQPM) project may be deployed, in accordance with variousembodiments of the present disclosure;

FIG. 2 is an exemplary implementation of a series of activitiesperformed for the PQPM project, according to an embodiment of thepresent disclosure.

FIG. 3 is an exemplary implementation of the GUI module for facilitatingthe PQPM project, according to an embodiment of the present disclosure;

FIG. 4 is an exemplary user interface window for creating a PQPMproject, according to an example embodiment of the present disclosure;

FIG. 5 is an exemplary user interface window for receiving informationassociated with the PQPM project, according to an example embodiment ofthe present disclosure;

FIG. 6 is an exemplary user interface for displaying the informationassociated with the new PQPM project, according to an example embodimentof the present disclosure.

FIG. 7 is an exemplary user interface window for editing informationassociated with the PQPM project, according to an example embodiment ofthe present disclosure;

FIG. 8 is an exemplary user interface window to add part informationfrom an engineering data system, for the PQPM project, according to anexample embodiment of the present disclosure;

FIG. 9 is an exemplary user interface window to add part informationfrom a team center, for the PQPM project, according to an exampleembodiment of the present disclosure;

FIG. 10 is an exemplary user interface window add supplier informationfor the PQPM project, according to an example embodiment of the presentdisclosure;

FIG. 11 is an exemplary user interface window to add a New ProductInformation (NPI) program associated with the PQPM project, according toan example embodiment of the present disclosure;

FIG. 12 is an exemplary user interface window for displaying the addedNPI program to the PQPM project, according to an example embodiment ofthe present disclosure;

FIG. 13 is an exemplary user interface window for adding a sessionassociated with the PQPM project, according to an example embodiment ofthe present disclosure;

FIG. 14 is an exemplary user interface window for displaying a summaryof the PQPM project with expanded sub-activities for PQPM activitieswithin the PQPM project, according to an example embodiment of thepresent disclosure;

FIG. 15 is an exemplary user interface window for displaying a summaryof the PQPM project with collapsed sub-activities for the PQPMactivities within the PQPM project, according to an example embodimentof the present disclosure;

FIG. 16 is an exemplary user interface window for adding a team memberto the PQPM project, according to an example embodiment of the presentdisclosure;

FIG. 17 is an exemplary user interface window for searching the teammember for the PQPM project, according to an example embodiment of thepresent disclosure;

FIG. 18 is an exemplary user interface window for linking sub-activitiesto the team member for the PQPM project, according to an exampleembodiment of the present disclosure;

FIG. 19 is an exemplary user interface window for displaying informationassociated with one or more activities associated with the PQPM project,according to an example embodiment of the present disclosure;

FIGS. 20-24 are exemplary user interface windows for receivinginformation associated with one or more sub-activities associated withthe PQPM project, according to an example embodiment of the presentdisclosure;

FIG. 25 is an exemplary user interface window for adding an issue forone or more sub-activities within the PQPM project, according to anexample embodiment of the present disclosure;

FIG. 26 is an exemplary user interface window for adding an attachmentfor one or more sub-activities within the PQPM project, according to anexample embodiment of the present disclosure;

FIG. 27 is an exemplary user interface window for displaying real timeupdated summary of the PQPM project, according to an example embodimentof the present disclosure;

FIG. 28 is an exemplary user interface window for adding a parentproject to the PQPM project, according to an example embodiment of thepresent disclosure;

FIG. 29 is an exemplary user interface window for searching the parentproject for the PQPM project, according to an example embodiment of thepresent disclosure;

FIG. 30 is an exemplary user interface window for linking one or moresub-activities to the parent project for the PQPM project, according toan example embodiment of the present disclosure;

FIG. 31 is an exemplary user interface window for displaying one or morePQPM projects associated with a team member, according to an exampleembodiment of the present disclosure;

FIG. 32 is an exemplary user interface window for displaying one or moresub-activities within one or more PQPM projects associated with a teammember, according to an example embodiment of the present disclosure;

FIG. 33 is an exemplary user interface window for receiving informationfrom the team member to generate an NPI project report for PQPMconformance for one or more PQPM projects within an NPI program, inaccordance with an example embodiment of the disclosure.

FIGS. 34-35 are exemplary user interface windows to display the NPIproject report for PQPM conformance, in accordance with an exampleembodiment of the disclosure.

FIG. 36 is an exemplary user interface window for receiving informationfrom the team member to generate an NPI project view report for one ormore PQPM projects within an NPI program, in accordance with an exampleembodiment of the disclosure.

FIG. 37 is an exemplary user interface window to display the NPI projectview report, in accordance with an example embodiment of the disclosure.

FIG. 38 is an exemplary user interface window for receiving informationfrom the team member to generate a PQPM risk report for one or more PQPMprojects within an NPI program, in accordance with an example embodimentof the disclosure.

FIG. 39 is an exemplary user interface window to display the PQPM riskreport, in accordance with an example embodiment of the disclosure.

FIG. 40 is an exemplary user interface window for receiving informationfrom the team member to generate a PQPM NPI gateway report for one ormore PQPM projects within an NPI program, in accordance with an exampleembodiment of the disclosure.

FIG. 41 is an exemplary user interface window for receiving additionalinformation from the team member to generate the PQPM NPI gateway reportfor one or more PQPM projects within an NPI program, in accordance withan example embodiment of the disclosure.

FIG. 42 is an exemplary user interface window to display the PQPM NPIgateway report, in accordance with an example embodiment of thedisclosure.

FIG. 43 is a block diagram of an exemplary computer-based system,according to an example embodiment of the present disclosure; and

FIG. 44 is an exemplary process flow for facilitating the PQPM project,according to an example embodiment of the present disclosure.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments in the disclosureherein makes reference to the accompanying drawings and figures, whichshow the exemplary embodiments by way of illustration only. While theseexemplary embodiments are described in sufficient detail to enable thoseskilled in the art to practice the disclosure, it should be understoodthat other embodiments may be realized and that logical and mechanicalchanges may be made without departing from the spirit and scope of thedisclosure. It will be apparent to a person skilled in the pertinent artthat this system can also be employed in a variety of otherapplications. Thus, the detailed description herein is presented forpurposes of illustration only and not of limitation. For example, thesteps recited in any of the method or process descriptions may beexecuted in any order and are not limited to the order presented.

The present disclosure is described herein with reference to blockdiagrams and flowchart illustrations of methods, and computer programproducts according to various aspects of the disclosure. It will beunderstood that each functional block of the block diagrams and theflowchart illustrations, and combinations of functional blocks in theblock diagrams and flowchart illustrations, respectively, can beimplemented by computer program instructions.

These computer program instructions may be loaded onto a general purposecomputer, special purpose computer, or other programmable dataprocessing apparatus to produce a machine, such that the instructionsthat execute on the computer or other programmable data processingapparatus create means for implementing the functions specified in theflowchart block or blocks. These computer program instructions may alsobe stored in a computer-readable memory that can direct a computer orother programmable data processing apparatus to function in a particularmanner, such that the instructions stored in the computer-readablememory produce an article of manufacture including instruction meanswhich implement the function specified in the flowchart block or blocks.The computer program instructions may also be loaded onto a computer orother programmable data processing apparatus to cause a series ofoperational steps to be performed on the computer or other programmableapparatus to produce a computer-implemented process such that theinstructions which execute on the computer or other programmableapparatus provide steps for implementing the functions specified in theflowchart block or blocks.

Accordingly, functional blocks of the block diagrams and flow diagramillustrations support combinations of means for performing the specifiedfunctions, combinations of steps for performing the specified functions,and program instruction means for performing the specified functions. Itwill also be understood that each functional block of the block diagramsand flowchart illustrations, and combinations of functional blocks inthe block diagrams and flowchart illustrations, can be implemented byeither special purpose hardware-based computer systems which perform thespecified functions or steps, or suitable combinations of specialpurpose hardware and computer instructions. Further, illustrations ofthe process flows and the descriptions thereof may make reference touser windows, prompts, etc. Practitioners will appreciate that theillustrated steps described herein may comprise in any number ofconfigurations including the use of windows, hypertexts, hyperlinks,popup windows, prompts and the like. It should be further appreciatedthat the multiple steps as illustrated and described may be combinedinto single windows but have been expanded for the sake of simplicity.In other cases, steps illustrated and described as single process stepsmay be separated into multiple windows but have been combined forsimplicity.

It is further noted that a “user device” may include, for example, anyof computer, laptop, mobile phone, cellular telephones, beepers, pagers,iPods®, personal digital assistants (PDAs), Blackberry® type devicesand/or any device capable of receiving and presenting emails.

The systems, methods and computer program products disclosed inconjunction with various embodiments of the present disclosure areembodied in systems and methods for facilitating Product QualityPlanning and Management (PQPM) during a product development cycle.

The present disclosure is described in more detail herein in terms ofthe above disclosed exemplary embodiments of system, processes andcomputer program products. This is for convenience only and is notintended to limit the application of the disclosure. In fact, afterreading the following description, it will be apparent to one skilled inthe relevant art(s) how to implement the following system in alternativeembodiments.

FIG. 1 is an overview of an exemplary environment 100 for facilitating aPQPM project, in accordance with various embodiments of the presentdisclosure. The environment 100 includes a server 102, a repository 104,a user device 106, a communication network 108 and a Graphical UserInterface (GUI) module 110. The server 102, the repository 104, the userdevice 106 and the GUI module 110 may communicate with each other overthe communication network 108. Examples of the communication network 108may include a wide area communication network (WAN), a local areacommunication network (LAN), an Ethernet, Internet, an Intranet, acellular communication network, a satellite communication network, orany other suitable communication network for transmitting data. Thecommunication network 108 may be implemented as a wired communicationnetwork, a wireless communication network or a combination thereof. Inan embodiment, the GUI module 110 may be accessed through the server102, by the user device 106 for facilitating the PQPM project associatedwith one or more parts or components of a product in the productdevelopment cycle.

User device 106 may be any device capable of communicating with theserver 102 and the GUI module 110. In one embodiment, a user (hereinafter referred to as a team member) may have the user device 106 tocommunicate with the server 102 of an organization, on which the GUImodule 110 may be deployed. In one example, the user device 106 may be adata processing system such as, for example, a mobile device, anysuitable personal computer, a laptop, minicomputer, Personal DigitalAssistant (PDA), or the like. Those skilled in art can appreciate thatuser device 106 includes an operating system (e.g., Windows NT,95/98/2000, OS2, UNIX, Linux, Solaris, MacOS, etc.) as well as variousconventional support software and drivers typically associated withcomputer. The user device 106 may also include an internal memory, anexternal memory and a cache. The user device 106 may also include one ormore browsers (e.g., Microsoft® Internet explorer, Mozilla® Firefox,etc.) through which an email server may be accessed. Alternatively, theuser device 106 may include a user email program such as a Microsoft®Outlook, Mozilla® Thunderbird, Pegasus® Mail, and the like, fordownloading, reading, replying and/or forwarding the email. Although, asingle user device 106 is illustrated herein for exemplary purposes, oneskilled in art can appreciate that there can be more than one userdevice.

The repository 104 and/or one or more databases associated with the GUImodule 110 may employ any type of database, such as relational,hierarchical, graphical, object-oriented, and/or other databaseconfigurations. Common database products that may be used to implementthe databases include DB2 by IBM (White Plains, N.Y.), various databaseproducts available from Oracle Corporation (Redwood Shores, Calif.),Microsoft Access or Microsoft SQL Server by Microsoft Corporation(Redmond, Wash.), or any other suitable database product. Moreover, thedatabases may be organized in any suitable manner, for example, as datatables or lookup tables. Each record may be a single file, a series offiles, a linked series of data fields or any other data structure.Association of certain data may be accomplished through any desired dataassociation technique such as those known or practiced in the art. Forexample, the association may be accomplished either manually orautomatically. Automatic association techniques may include, forexample, a database search, a database merge, GREP, AGREP, SQL, using akey field in the tables to speed searches, sequential searches throughall the tables and files, sorting records in the file according to aknown order to simplify lookup, and/or the like. The association stepmay be accomplished by a database merge function, for example, using a“key field” in pre-selected databases or data sectors.

More particularly, a “key field” partitions the database according tothe high-level class of objects defined by the key field. For example,certain types of data may be designated as a key field in a plurality ofrelated data tables and the data tables may then be linked on the basisof the type of data in the key field. The data corresponding to the keyfield in each of the linked data tables is preferably the same or of thesame type. However, data tables having similar, though not identical,data in the key fields may also be linked by using AGREP, for example.In accordance with one aspect of the system, any suitable data storagetechnique may be utilized to store data without a standard format. Datasets may be stored using any suitable technique, including, for example,storing individual files using an ISO/DEC 7816-4 file structure;implementing a domain whereby a dedicated file is selected that exposesone or more elementary files containing one or more data sets; usingdata sets stored in individual files using a hierarchical filing system;data sets stored as records in a single file (including compression, SQLaccessible, hashed via one or more keys, numeric, alphabetical by firsttuple, etc.); Binary Large Object (BLOB); stored as ungrouped dataelements encoded using ISO/IEC 7816-6 data elements; stored as ungroupeddata elements encoded using ISO/IEC Abstract Syntax Notation (ASN.1) asin ISO/IEC 8824 and 8825; and/or other proprietary techniques that mayinclude fractal compression methods, image compression methods, etc.

In one exemplary embodiment, the ability to store a wide variety ofinformation in different formats is facilitated by storing theinformation as a BLOB. Thus, any binary information can be stored in astorage space associated with a data set. The BLOB method may store datasets as ungrouped data elements formatted as a block of binary via afixed memory offset using one of fixed storage allocation, circularqueue techniques, or best practices with respect to memory management(e.g., paged memory, least recently used, etc.). By using BLOB methods,the ability to store various data sets that have different formatsfacilitates the storage of data associated with the system by multipleand unrelated owners of the data sets. For example, a first data setwhich may be stored may be provided by a first party, a second data setwhich may be stored may be provided by an unrelated second party, andyet a third data set which may be stored, may be provided by an thirdparty unrelated to the first and second party. Each of these threeexemplary data sets may contain different information that is storedusing different data storage formats and/or techniques. Further, eachdata set may contain subsets of data that also may be distinct fromother subsets.

In one embodiment, a team member may create a PQPM project on a userinterface 112 and subsequently, the GUI module 110 may display theactivities that need to be executed by the team members assigned to thePQPM project. The activities may include sub-activities that need to beexecuted for a successful completion of the PQPM project. The teammembers assigned to the PQPM project may review the various expectationsassociated with each of the sub-activities within the correspondingactivities and execute various tasks required to reach thoseexpectations. In an embodiment, the activities and associatedsub-activities may be standard PQPM activities as listed in theforegoing paragraphs. In an embodiment, the GUI module 110 may receivetextual inputs indicative of a measurement criterion associated with anexecution status of the activities. Subsequently, The GUI module 110 mayenable the team members to track a progress of the PQPM project based onthe measurement criterion associated with the execution status of theactivities. Further, the GUI module 110 may enable the team members tovisually monitor a risk associated with the PQPM project and theassociated NPI program. The GUI module 110 may develop plurality of riskcharts to provide a risk status associated with the various componentsof the product during the product development cycle. In an embodiment,the risk charts are developed based on the measurement criterionindicative of the execution status of the activities.

As illustrated in FIG. 2, the team members may execute the activities inan independent manner or in a dependent manner as required, when one ormore activities are linked together. In one embodiment, these activitiesmay be related to different stages and processes performed during thedevelopment cycle of every part or component of a product. It may beapparent to a person of ordinary skill in the art that the activitiesand associated sub-activities described in FIG. 2 are merely exemplaryand do not limit the scope of the disclosure.

As illustrated in FIG. 2, the team member may execute a requirementsmanagement activity 202 for the PQPM project. For example, therequirements management activity 202 may be understood as the designcriteria and the program requirements necessary to initiate the PQPMproject. Further, the design criteria and the program requirements mayinclude design goals, reliability and quality goals, program timing,affordable cost targets, capacity planning volumes, key contactpersonnel, and input requested from and supplied by one or more involvedmanufacturing facilities. As will be understood by a person havingordinary skill in the art, the requirements management activity 202 isperformed to assure that any existing manufacturing and process issuesare addressed appropriately by the new design and process, early in theproduct development cycle.

In one embodiment, the requirement management activity 202 may utilize aQuality Function Deployment (QFD) 204 for performing the requirementsmanagement 202 activity. The QFD 204 may be understood as a process thatdefines, organizes, analyzes and evaluates customer and business needsin the form of the Voice Of Customer (VOC) 206 and Voice Of Business(VOB) 206. Further, the QFD 204 may convert the customer and businessneeds, into system design requirements, the system design requirementsinto part characteristics, subsequently converts part characteristicsinto production requirements and production requirements into productionoperations.

In one embodiment, the requirements management activity 202 may furtherinclude a plurality of sub-activities to be executed. As will beunderstood by a person having ordinary skill in the art, thesub-activities may include a predefined expectation that defines theexpected result of the sub-activity execution. The requirementsmanagement activity 202 may include a generate capacity planning volumeassumptions sub-activity. In an exemplary embodiment, the expectationsassociated with the generate capacity planning volume assumptionssub-activity may include “the New Product Introduction (NPI) team hasgenerated capacity planning volume assumptions and have contingencies inplace for any deviations from these volumes.”

Further, the requirements management activity 202 may include a developcritical customer and business requirements sub-activity. In anexemplary embodiment, the expectations associated with this sub-activitymay include “all the critical customer requirements have beenestablished and then translated into specific technical objectives,product objectives, or technical specifications. These specificationslist the things, which the part under development needs to comply with.”

Furthermore, the requirements management activity 202 may include adevelop project plan sub-activity. In an exemplary embodiment, theexpectation associated with this sub-activity may include “that aproject plan has been developed which supports the design & developmentof the part of the product. It is detailed to illustrate key milestonesand activities around specific build events (prototype & pilot builds),drawing release dates, Material Required by Date (MRD), validationtesting, etc. The project plan may be reviewed on regular basis toensure that the design & development process timing is kept on track.”

Further, the team member may execute a quality history & lessons learnedactivity 208. The quality history & lessons learned activity 208 may beunderstood as a list of all historical quality information that may begathered to assess the potential for the existing issues to reoccurduring at any stage during the design, manufacturing installation anduse of the product under development. As will be understood by a personhaving ordinary skill in the art, it is important that the issues arenot carried through to the new version/design of the product.

In one embodiment, the quality history & lessons learned activity 208may include an update carry over quality sub-activity. In an exemplaryembodiment, the expectations associated with the update carry overquality sub-activity may include “that a list of all historical qualityconcern/issues be prepared by a design authority to assess the potentialfor reoccurrence during the design, manufacture, installation and use ofthe product. The list may include, warranty information, internalquality indicators for current product, supplier quality reports, fieldreturn product analysis, etc.”

In various embodiments of the disclosure, an activity may be linked witheach other and may be executed based on inputs and outputs from theexecution of other activities. For example, the Design Failure Mode andEffect Analysis (DFMEA) activity 210 may receive an input from theexecution of the quality history & lessons learned activity 208 and froma pro-active reliability 211. The linkages of all the activities areillustrated in FIG. 2 with the relevant arrow heads.

Subsequently, the team member may perform a design failure mode andeffect analysis (DFMEA) activity 210. The DFMEA activity 210 may beunderstood as a systematic approach, used by a design responsible team,to assure that potential design failure modes and their associatedcauses have been considered and addressed. DFMEAs are to be doneconcurrently with the design process to allow the determined recommendedactions to positively affect the design.

In one embodiment, the DFMEA activity 210 may utilize a boundary diagram212, an interface analysis 214, a P-diagram 216, and a noise factormanagement 218 for performing the DFMEA activity 210. As will beunderstood by a person having ordinary skill in the art, the boundarydiagram 212 is a graphical representation of a system, sub-system or acomponent illustrating the physical relationships and interactionsbetween them and the surroundings. The surrounding may include theenvironment, end-user, other sub-systems and components. Further, theboundary diagrams 212 help in defining the scope of the DFMEA activity210.

Further, the interface analysis 214 may be performed to analyze andmanage the interfaces between a system and its surrounding systems. Theinterface analysis 214 may identify system interfaces and the effects ofthese interfaces on the system of focus and the interfacing systems. Theinterface analysis 214 may document, quantify, and prioritize systeminterface details. Further, a P-diagram 216 may be a tool used tosupport the development of transfer functions, noise factor, managementstrategies, FMEAs and verification methods. The P-Diagram 216 provides astructured method to identify intended outputs (output signals),intended inputs (input signals), ideal relationship between input andoutput, uncontrolled (or uncontrollable) factors that impact output(Noises), unintended outputs (error states or failure modes) and designcontrol factors. Further, the noise factor management 218 may beunderstood as the management of the factors that affect the output, suchthat the noise factor is minimized or eliminated.

Further, the team member may need to execute a plurality ofsub-activities associated with the DFMEA activity 210. The team membermay execute a plan product and system FMEAs sub-activity within theDFMEA activity 210. In an exemplary embodiment, the expectationsassociated with the plan product and system FMEAs sub-activity mayinclude, “that a plan to be developed to execute product and systemFMEAs based on high risk systems and components. The sub-activity maydefine the overall responsibilities for the DFMEA plan. The DFMEAs maybe selected to be completed using a method for focusing on the changesin the design, and the corresponding effects on the entire system, andnot the entire design.”

Further, the team member may execute a Complete FMEAs sub-activitywithin the DFMEA activity 210. In an exemplary embodiment, theexpectations associated with the Complete FMEAs sub-activity may include“preparing an initial design FMEA using the standard guidelines, such asAutomotive Industry Action Group (AIAG) standard, and using theappropriate inputs from other quality tools. Also, the DFMEA shouldaddress all lessons learned and known quality and warranty issues. Asexplained previously, the Complete FMEAs sub-activity may utilize theQFD 204, the boundary diagrams 212, the interface analysis 214, theinternal/external quality history 208, P-diagram 216, pass throughcharacteristics and robustness evaluation. In a further embodiment, theoutput of the sub-activity may be a DFMEA that lists and details all thepotential failure modes associated with the component under developmentand the recommended or preventative or corrective actions which havebeen prioritize by high severity, impacting government regulation orsafety issues, or high criticality or a Risk Priority Number (RPN)value. Further, the recommended actions may include the responsiblelead, timing for completion, identification of the specialcharacteristics that need to be taken into consideration for a ProcessFMEA (PFMEA) and the corresponding control plans, etc.

Subsequently, the team member may execute an update FMEAs stage 1sub-activity. In an exemplary embodiment, the expectations associatedwith the update FMEAs stage 1, may include “revisiting the initialDesign FMEA based upon updates from the component development processusing the latest AIAG guidelines.” Furthermore, the team member mayexecute an update FMEAs stage 2 sub-activity. In an exemplaryembodiment, the expectations associated with the update FMEAs stage 2sub-activity may include revisiting the initial Design FMEA based uponupdates from the completion of design validation testing, and prototypetesting using the latest AIAG guidelines.

Further, the team member may execute a drawings & specificationsactivity 220, as illustrated in FIG. 2. In one embodiment, the drawings& specifications activity 220 may evaluate the development of targetsand specifications as they are defined to be input to the designprocess, and to the drawings (including all engineering drawings, CADdata, material specifications and engineering specifications). In anembodiment the DFMEA activity 210 receives an input from the executionof the drawings & specifications activity 220.

Further, the team member may execute a plurality of sub-activitiesassociated with the drawings & specifications activity 220. The drawings& specifications activity 220 may include a plan the Bill of Material(BOM) sub-activity. In an exemplary embodiment, the expectationsassociated with the plan the bill of material sub-activity may includethat a plan has been developed that identifies the requirements fordrawings and specifications that support program milestones and requireddesign target dates. Further the overall responsibility for the designplan may be clearly defined.

Further, the team member may execute a complete the Bill of Material(BOM) sub-activity within the drawings & specifications activity 220. Inan exemplary embodiment, the expectations associated with the completethe BOM sub-activity may specify that the BOM is completed and releasedin time to support prototype builds and/or validation activities.Subsequently, the team member may execute an update drawings &specifications sub-activity. For example, the expectations associatedwith the update drawings & specifications sub-activity may specify thatthe released drawings may include the appropriate SpecialCharacteristics, 1E Specifications and special notes, as required.Additionally, the drawings may also conform to general drawing standardsof the organization.

Furthermore, the team member may execute a production release theproduct design sub-activity. In an example, the expectations associatedwith the production release the product design sub-activity may indicatethat all the drawings are production released in time to support theproduction trial run (pilot build).

The team member may further execute a Design Verification Plan andReport (DVP&R) activity 222 that may list the engineering evaluationsand tests required to establish that the design is fit for use in itsintended environment. In one embodiment, the DVP&R activity 222 mayinclude a one or more sub-activities that may be executed to completethe execution of the DVP&R activity 222. The team member may execute adevelop DVP&R sub-activity. For example, the expectations associatedwith the develop DVP&R sub-activity may specify that a DesignVerification Plan (DVP) has been developed to support the programrequirements identified through the DFMEA (e.g., functionalrequirements, regulatory requirements, etc.). Further, the overallresponsibility for the plan is clearly defined and has been communicatedto the appropriate personnel. Furthermore, the DVP&R lists the detectionand prevention controls corresponding to the failure modes identified inthe DFMEA.

Further, the team member may execute a complete DVP&R sub-activity. Inan exemplary embodiment, the expectations associated with the completeDVP&R sub-activity may specify that the roles and responsibilitieswithin the DVP have been agreed to ensure that each test requirement iscompleted to support the customer development program. Subsequently, theteam member may execute an update validation plan. For example, theexpectations associated with the update validation plan may indicatethat the DVP&R lists the methods, equipment, design level, statisticalacceptance criteria, sample sizes, and results of all the engineeringevaluations and tests, and completed by the gateway 5.

The team member may further execute a design/manufacturing review(s)activity 224 that may indicate that for suppliers, design reviews areregularly scheduled meetings led by a supplier's design activity andmust include other affected areas. Further manufacturing reviews areregularly scheduled meetings used to monitor the status of themanufacturing process development. The design reviews may be held by aprogram team. Manufacturing Reviews are reviews of the manufacturingdesign, tooling, equipment & facilities.

In one embodiment, the design/manufacturing review(s) activity 224 mayinclude a one or more sub-activities that may be executed to completethe execution of the design/manufacturing review(s) activity 224. Theteam member may execute a conduct design review 1 sub-activity. Forexample, the expectations associated with the conduct design review 1sub-activity may specify that a plan has been developed to establishregular reviews with the appropriate cross-functional team. Further,participation may include design engineering, technical leads,manufacturing engineering, product support, appropriate levels ofmanagement, etc., as applicable. Additionally the overall responsibilityfor the plan may be clearly defined.

The team member may execute a conduct design review 2&3 sub-activity.For example, the expectations associated with the conduct design review2&3 sub-activity may specify that the teams may meet at least oncebefore the gateway 3 review, to ensure all the existing issues areunderstood and the mitigating actions are associated with them, as theoutput from these reviews are often used to support next level NPIreview. Subsequently, the team member may execute a conduct designreview 4 sub-activity. For example, the expectations associated with theconduct design review 4 sub-activity may specify that the teams may meetagain at least once before the gateway 4 review, to ensure all theissues are understood and the corresponding mitigating actions areassociated with them, as the output from these reviews are often used tosupport next level NPI review. Similarly, the team member may execute aconduct design review 5 sub-activity. For example, the expectationsassociated with the conduct design review 5 sub-activity may specifythat the teams may meet at least once before the gateway 5 review, toensure all the issues are understood and the mitigating actions areassociated with them, as the output from these reviews are often used tosupport next level NPI review. Furthermore, the team member may beconfigured to execute a conduct design review 6 sub-activity. Forexample, the expectations associated with the conduct design review 6sub-activity may specify that the teams may meet at least once beforethe gateway 6 review, to ensure all the existing issues are understoodand the mitigating actions are associated with them, as the output fromthese reviews are often used to support next level NPI review

The team member may further execute a team feasibility and managementcommitment activity 226 that may determine whether the proposed designcan be manufactured within the guidelines and specifications. Forexample, a cross-functional design/manufacturing review team is chargedwith assessing design feasibility. Once the feasibility is established,the program organization undertakes the responsibility for thedesign/manufacturing review process and reassessing feasibility for anydesign/part change that may occur.

In one embodiment, the team feasibility and management commitmentactivity 226 may include a one or more sub-activities that may beexecuted to complete the execution of the team feasibility andmanagement commitment activity 226. The team member may execute a teamfeasibility review sub-activity. For example, the expectationsassociated with the team feasibility review sub-activity may specifythat team feasibility meetings should be held at regular intervals, inorder for the team to come to a consensus that the product under reviewcan continue to the next gateway, either with or without managementreview. A plan may be developed that defines when the team will meet inorder to sign off the team feasibility documents. Further, the teamfeasibility documents may be in line with higher level NPI programmeetings.

The team member may further execute a complete start of development teamfeasibility sub-activity. For example, the expectations associated withthe complete start of development team feasibility sub-activity mayspecify that once the supplier selection process has been completed anda supplier has been nominated, then the start of development teamfeasibility should be completed. This is to ensure the all aspects ofthe product under development are considered.

The team member may further execute a complete team feasibilityagreement sub-activity. For example, the expectations associated withthe complete team feasibility agreement sub-activity may specify that insupport of the higher level NPI program the team may review the PQPMWorkbook, and declare a status associated with the development processon the team feasibility document associated with the gateway 3. The teammay continue if there are no issues with the development process, andtherefore it is on plan to deliver all the customer expectations.Further, the team may mark the status as “Feasible” if there are anumber of issues, which have mitigating action identified, and thedevelopment process can continue without the need for management review.Furthermore, the team may mark the status as “Not Feasible”, if thereare a number of issues, which may have mitigating actions, however, thedevelopment process may be held until management review.

The team member may further execute a status review for team feasibilityGW4 sub-activity. For example, the expectations associated with thestatus review for team feasibility GW4 sub-activity may specify that insupport of a higher level NPI program the team may review the PQPMworkbook, and declare a status associated with the development processon the team feasibility document GW4, as illustrated for Complete TeamFeasibility Agreement sub-activity.

The team member may further execute a status review for team feasibilityGW5 sub-activity. For example, the expectations associated with thestatus review for team feasibility GW5 sub-activity may specify that insupport of a higher level NPI program the team may review the PQPMworkbook, and declare a status associated with the development processon the team feasibility document GW5, as illustrated for complete teamfeasibility agreement sub-activity.

The team member may further execute a status review for team feasibilityGW6 sub-activity. For example, the expectations associated with thestatus review for team feasibility GW6 sub-activity may specify that insupport of a higher level NPI program the team may review the PQPMworkbook, and declare a status associated with the development processon the team feasibility document GW6, as illustrated for complete teamfeasibility agreement sub-activity.

The team member may further execute a special characteristics activity228 that may identify all the product and process specialcharacteristics. The team may either eliminate them by designing thefailure modes out of the product, or by putting the appropriatemitigating controls into the manufacturing process, so that the failuremode is not seen by the customer. As will be understood by a personhaving ordinary skill in the art, that all the special characteristicsbe clearly identified throughout the quality documentation, specificallyin the control plans of the project.

In one embodiment, the special characteristics activity 228 may includea one or more sub-activities that may be executed to complete theexecution of the special characteristics activity 228. The team membermay execute a develop preliminary characteristics sub-activity 230. Forexample, the expectations associated with the develop preliminarycharacteristics sub-activity 230 may specify that all pass throughcharacteristics and nominated special characteristics (SCs) from theinitial Design and process FMEAs are identified and included in thePrototype (Prove Design Build) Control Plan.

The team member may further execute a confirm special characteristicsfor pilot control plan sub-activity 232. For example, the expectationsassociated with the confirm special characteristics for pilot controlplan sub-activity 232 may specify that all pass through characteristicsand nominated Special Characteristics (SCs) from the design and processFMEAs are identified and included in the pre launch (pilot componentbuilds) control plan.

The team member may further execute a confirm special characteristicsfor production control plan sub-activity. For example, the expectationsassociated with the confirm special characteristics for productioncontrol plan sub-activity may specify that all pass throughcharacteristics and nominated Special Characteristics (SCs) from theDesign and Process FMEAs are clearly identified within the documentedPFMEA and are also clearly identified within the production controlplan.

The team member may further execute a facilities, tools & gaugesactivity 234 that may indicate that the facilities, tools, and gaugesare the additional, new, refurbished, and relocated resources requiredto produce the product at the customer specified quantity and qualitylevels. Expectations for this element may include but are not limited toplanning, statistical and acceptance criteria, lean manufacturingconsiderations, qualification of equipment, corrective actions, deliveryand setup.

In one embodiment, the facilities, tools & gauges activity 234 mayfurther include a one or more sub-activities that may be executed tocomplete the execution of the facilities, tools & gauges activity 234.For example, the team member may execute an identify new equipment,tooling and facilities & identify gauge and test requirementssub-activity. For example, the expectations associated with the identifynew equipment, tooling and facilities & identify gauge and testrequirements sub-activity may specify that a work plan has beendeveloped for all tooling, equipment, test equipment, gauges andfixtures. The plan may include responsible lead, timing, validationmethods and respective acceptance criteria. All timing must supportavailability of production tools/gages for production trial run (pilotbuild). In addition, the plan has also been agreed to by all partiesinvolved in the project.

Further, the team member may execute an all capital expenses requestshave been approved and purchase orders have been released sub-activity.For example, the expectations associated with the all capital expensesrequests have been approved and purchase orders have been releasedsub-activity may specify that all capital expenses requests have beenapproved and purchase orders have been released.

Further, the team member may execute a validate tooling, equipment, testequipment, gauges and fixtures for production trial run (pilot build)sub-activity. In an exemplary embodiment, the expectations associatedwith the validate tooling, equipment, test equipment, gauges andfixtures for production trial run (pilot build) sub-activity may specifythat all of the component tooling, equipment, test equipment, gauges andfixtures are delivered, validated and commissioned on time to supportthe production trial run (pilot build).

The team member may further execute a prototype (prove design) buildcontrol plan activity 236 that may be a description of the dimensionalmeasurements, material, and functional tests that will occur during theconfirmation prototype (prove design) Build. In one embodiment, theprototype (prove design) build control plan activity 236 may include aone or more sub-activities that may be executed to complete theexecution of the prototype (prove design) build control plan activity236.

For example, the team member may execute a “work plan for identifyingwhere prototype (prove design) build control plans are required”sub-activity. For example, the expectations associated with the workplan for identifying where prototype (prove design) build control plansare required sub-activity may specify that a work plan has beendeveloped to identify where prototype (prove design) build control plansare required. Additionally, the plan identifies the responsible lead andsupports availability by the start of the prototype (prove design)build.

Further, the team member may execute a “develop manufacturing prototypecontrol plans” sub-activity. For example, the expectations associatedwith the “develop manufacturing prototype control plans” sub-activitymay specify that the prototype (prove design build) control plans havebeen developed in accordance with standard AIAG format, and have beensigned off by all responsible parties. The prototype control Plans maybe created with input from the historical control plans, DFMEA, PFMEA,preliminary drawings and specifications, etc.

The team member may further execute a prototype (prove design) buildactivity 238 that may identify the required manufacture or assembly ofcomponents, sub-systems, systems, or assembled machines (e.g.prototype/prove design) that may be supplied to the customer and builtprior to the pre-production trial run. In one embodiment, the prototype(prove design) build activity 238 may include a one or moresub-activities that may be executed to complete the execution of theprototype (prove design) build activity 238.

For example, the team member may execute a “develop manufacturingprototype test plan” sub-activity. In an exemplary embodiment, theexpectations associated with the “develop manufacturing prototype testplan” sub-activity may specify that a work plan has been developed todefine the prototype (prove design) build. The plan may identifyresponsible leads, and timing and quantity of each individual event inthe build. Further, the plan has been agreed to by all parties andcommunicated to all lower level systems/components to ensure partsavailability at the start of the prototype (prove design) build.

Furthermore, the team member may execute a “complete manufacturingprototype testing” sub-activity. In an exemplary embodiment, theexpectations associated with the “complete manufacturing prototypetesting” sub-activity may specify that the prototype builds arecompleted with design representative parts, using prototype (provedesign) control plans and appropriate gauging as identified in thecontrol plans. Further, all identified issues from the prototype buildmay be documented, assigned to responsible lead, and communicated toappropriate parties. Additionally, all the identified issues have a planfor full resolution by production trial run (pilot build).

The team member may further execute a manufacturing process flowchartactivity 240 that may be a graphic representation of the current orproposed sequence of manufacturing process. In one embodiment, themanufacturing flow chart can be either in the traditional flow chartformat, or depicted in cycle line layouts, tooling line layouts, plantlayouts, or other appropriate types of layouts, providing all necessaryinformation. In a further embodiment, the manufacturing processflowchart activity 240 may include a one or more sub-activities that maybe executed to complete the execution of the manufacturing processflowchart activity 240.

Further, the team member may execute a “plan the process flow charts”sub-activity. In an exemplary embodiment, the expectations associatedwith the “plan the process flow charts” sub-activity may specify that aplan exists to develop the high-level process flow chart and 100% of theprocess flow charts identified as high risk processes. Further, the teammember may execute a “develop process flowchart” sub-activity. In anexemplary embodiment, the expectations associated with the “developprocess flowchart” sub-activity may specify that the manufacturingprocess flowchart is a complete pictorial representation of all thevarious processes/operations, covering the entire process from receivingof initial material through to shipping of the finished product.Additionally, it may also include how the material is transportedbetween processes/operations, and any rework and/or repair routings.Furthermore, the flowchart may define the scope of the processes and/oroperations under study (similar to a boundary diagram) and may also beused to develop the PFMEA's and control plans (prototype, pilot buildand production). The flowchart may be developed using the standardtemplate, such as AIAG template. In a further embodiment, the flowchartmay include a description of events occurring at each operation,including the equipment and machine description. The nominated specialcharacteristics from the Design FMEAs and confirmed specialcharacteristics from the Process FMEAs may be identified and included inthe Flowchart.

In a further embodiment, the team member may execute an “update processflowcharts for Production Part Approval Process (PPAP) submission”sub-activity. For example, the PPAP may be understood as a process ofaddresses evaluation and documentation of the effects of a change (todesign or process) on the constituent parts and end products. In anexemplary embodiment, the expectations associated with the “updateprocess flowcharts for Production Part Approval Process (PPAP)submission” sub-activity may specify that the manufacturing processflowcharts are updated subsequent to the production trail run (PilotBuilds) and is ready to support the PPAP submission.

In a further embodiment, the team member may be configured to execute aProcess FMEA (PFMEA) activity 242 that is a systematic approach used bya manufacturing team to assure that potential process related failuremodes and their associated causes have been addressed and resolved. Themanufacturing process flow diagrams as well as a plurality of potentialspecial characteristics from the DFMEA activity may be used to ensurethat the process is analyzed in the appropriate sequence, with allfailure modes addressed. In a further embodiment, the process FMEAactivity 242 may include a one or more sub-activities that may beexecuted to complete the execution of the process FMEA activity 242.

In one embodiment, the team member may execute a “plan manufacturingprocess FMEAs” sub-activity for the activity 242. In an exemplaryembodiment, the expectations associated with the sub-activity mayspecify that a plan has been developed to execute the process FMEAs andincludes all priority processes identified and agreed by appropriatelevel of management. Further, the overall responsibility for the planmay be defined in the sub-activity.

Subsequently, the team member may execute a “complete manufacturingprocess FMEAs” sub-activity. In an exemplary embodiment, theexpectations associated with the “complete manufacturing process FMEAs”sub-activity may specify that an initial process FMEA may be preparedusing the latest AIAG guidelines or standard organizational guidelines.Further, the initial PFMEA may be prepared using the appropriate inputsfrom other quality tools. Further, the PFMEA may address ALL lessonslearned and known CPI, quality, and/or warranty issues. In oneembodiment, the typical inputs for preparing the initial PFMEA may be acorresponding DFMEA, QFD 204, Boundary Diagram 212, Interface Analysis214, Internal/external quality history 208, P-Diagram 216, “passthrough” characteristics and robustness evaluation. Further, the outputmay be a PFMEA that details all the potential failure modes associatedwith manufacturing process for the part or the component underdevelopment and the recommended preventative/corrective actions. In oneembodiment, the recommended actions may be prioritized based on a highseverity, impacting government regulation or safety issues, highcriticality, a risk priority number etc. As will be understood by aperson ordinarily skilled in the art, the recommended actions may detailthe responsible leader, timing for completion of the sub-activity, theidentification of the special characteristics that need to be consideredfor the control plans for the project.

Furthermore, the team member may execute a “review manufacturing processFMEAs” sub-activity. In an exemplary embodiment, the expectationsassociated with the “review manufacturing Process FMEAs” sub-activitymay specify that the PFMEA may be updated subsequent to the completionof a design verification phase of the development process. Subsequently,the team member may execute an “update manufacturing process FMEAs”sub-activity. In one exemplary embodiment, the expectations associatedwith the “update manufacturing process FMEAs” sub-activity may specifythat the PFMEA has been updated following product under development'spilot build, ready to support the PPAP submission.

In a further embodiment, the team member may execute a pre-launch (pilotbuild) control plan activity 244 that is a written description of thedimensional measurements and material and functional tests that mayoccur after the prototype builds and before the production builds. Inone embodiment, the plan may include the additional product and/orprocess controls to be implemented until the production process isvalidated. Further, the pre-launch (pilot build) control plan activity244 may include a one or more sub-activities to be executed to completethe execution of the activity 244.

In one embodiment, the team member may execute a “plan the pre-launch(pilot) build control plan” sub-activity. In an exemplary embodiment,the expectations associated with the “plan the pre-launch (pilot) buildcontrol plan” sub-activity may include a work plan for each Pre-Launch(Pilot) Build Control Plan that may define the responsible team leader,team members and timing. In one embodiment, the plan may be communicatedto all the responsible parties. Further, the team member may execute a“develop manufacturing pilot control plans” sub-activity. In exemplaryembodiments, the expectations associated with the “develop manufacturingpilot control plans” sub-activity may specify that the pre-launch (pilotbuild) control plans have been developed according to the AIAGstandards. In one embodiment, the inputs for the control plandevelopment may include, customer specifications, prototype buildcontrol plan, DFMEA revisions, PFMEA revisions, DVP Results,drawing/specification changes, measuring system analysis results linkedto the process flow diagram, etc. Further, the output of thesub-activity may be a control plan that may be easily understood andutilized by an operator. In one embodiment, the document may contain foreach line item/operation, the characteristics to be measured, method formeasuring the characteristics, the frequency of measurement, and areaction plan for any non-conforming items. In addition, all the specialcharacteristics (SCs) may be clearly identified within the control plan.

Further, the team member may execute an operator process instructionsactivity 246, as shown in FIG. 2. In one embodiment, the operatorprocess instructions activity 246 may describe the details of controlsand actions that an operating personnel may perform to produce qualityproducts. As will be understood, the operator process instructionsactivity 246 may further include a plurality of sub-activities forsuccessful execution.

In one embodiment, the team member may execute a “plan for developingoperator/process instructions” sub-activity under the activity 246. Invarious exemplary embodiments, the expectations associated with thesub-activity may indicate that a plan may specify the development ofoperator and/or process instructions. In one embodiment, the plan mayinclude a list of operator/process instructions to be completed, thedates of completion of the instructions, the responsible team leader forthe completion of the instructions, etc. In a further embodiment, theplan may identify if or when an operator training may be required to becompleted for one or more new operations, processes, or sequences.

In a further embodiment, the team member may execute an “assembleproduction documentation” sub-activity. In an example, the expectationsassociated with the sub-activity may indicate that the operatorinstructions may be easy to understand, accessible and be at applicablework station. Further, the document may be determined to be consistentwith the organizational guidelines and practices. Additionally, thedocument may include visual aids, and the work instructions that may beexecuted to meet the quality and process requirements.

Subsequently, the team member may execute a “complete productiondocumentation” sub-activity. In an example, the expectations associatedwith the sub-activity may indicate that the team may confirm completionof a training based on a predefined training plan. Further, the team mayensure that all operator training records are updated to indicate thatthe appropriate training is completed.

In an embodiment, the team member may execute a packaging specificationsactivity 248, as illustrated in FIG. 2. The packaging specificationsactivity 248 may execute to facilitate a supplier of a product to ensurethat the packaging is designed and developed to provide the protectionfrom normal transportation damage and adverse environmental factors.Further, the activity 248 may use one or more customer packagingstandards or generic packaging requirements.

In one embodiment, the team member may execute a “develop packagingspecifications plan” sub-activity within the activity 248. In exemplaryembodiments, the expectations associated with the “develop packagingspecifications plan” sub-activity may indicate that a plan specifies thedevelopment of the packaging specifications, for all level of productthat is to be supplied (e.g. prototype, pre-production, designverification, and production). In one embodiment, the plan may include alist of preferred suppliers for packaging, list of the packagingspecifications that need to be completed, the target dates forcompleting the packaging specifications, a one or more packaging trialrequired for completing the packaging specifications, etc. In oneembodiment, the packaging specification may additionally identify theresponsible team leader.

In a still further embodiment, the team member may execute an “identifypackaging standards” sub-activity. In various exemplary embodiments, the“identify packaging standards” sub-activity may indicate that an interimpackaging specification for prototype and pre-production product, may bespecified based on the customer requirements and/or standards. In oneembodiment, the customer requirements and standards may include a levelof required protection, ease of disposal of packaging, etc.

In an embodiment, the team member may execute a “finalize packagingrequirements” sub-activity. In an example, the expectations associatedwith the “finalize packaging requirements” sub-activity may indicatethat for any revision in the existing packaging specifications or a newpackaging specification, the packaging specifications may be developedbased on the customer's requirements and standards. In one embodiment,the packaging specification may also be based on environmentalrequirements of the location of the customer, associated governmentregulations for the location of the customer. Further, the packagingspecification may be documented for consistent application.Additionally, the packaging specification may be made available for thecustomers pilot build events.

Furthermore, the team member may execute an “evaluate packaging methods”sub-activity. In various examples, the “evaluate packaging methods”sub-activity may indicate that sufficient volumes of the productionpackaging may be available to support the start of productionrequirements. However, if the start of production volumes has a low rampup, then a plan may be executed to manage the introduction of additionalpackaging base on the volume ramp.

In a further embodiment, the team member may be configured to execute aMeasurement Systems Analysis (MSA) activity 250, as shown in FIG. 2. TheMSA activity 250 assesses the variation of the measurement system anddetermines whether the measurement system is acceptable for monitoringthe process.

Further, the team member may execute a “plan Measurement System Analysis(MSA) for gauges and test equipment” sub-activity within the MSAactivity 250. In exemplary embodiments, the “plan Measurement SystemAnalysis (MSA) for gauges and test equipment” sub-activity may indicatethat an existing plan may specify the development of the MeasurementSystem Analysis (MSA) for gauges and test equipment. In one embodiment,the plan may include a list of gauges and test equipment to bevalidated, a validation plan, acceptance criteria, number of parts, thecompletion dates for the analysis of gauges and test. Further, the planmay also identify the responsible lead for all MSA requirements.

Further, the team member may execute a “perform measurement systemsevaluation” sub-activity within the MSA activity 250. In exemplaryembodiments, the “perform measurement systems evaluation” sub-activitymay indicate that the measurement and evaluation technique for all thenominated special characteristics and/or special application gage andequipment, identified within the control plans, may under go a level ofevaluation based around the MSA, as defined by the AIAG standards. Forexample, a gauge study may be performed to ensure that the technique issuitable for the production environment as being used by the productionoperators, and ready to support the PPAP submission. Additionally, theoperator instruction and routine calibration plan may also bedocumented.

In an embodiment, the team member may execute a production trial run(pilot build) activity 252 The activity 252 is a validation of theeffectiveness of the manufacturing and assembly process, usingproduction tooling, equipment, environment (including productionoperators), facilities and cycle times. In one embodiment, the outputsfrom the production trial run in the form of parts & documentation areused to generate Production Part Approval (PPAP).

In an embodiment, the team member may execute a “plan production trialrun (pilot build) and Production Validation (PV) testing plan”sub-activity within the activity 252. In exemplary embodiments, theexpectations associated with the sub-activity may indicate that a planmay be developed for supporting production trial run (pilot build) andPV testing plan. For example, the availability of all production parts,production processes, and facilities may support the production trialrun (pilot build) Build timing. Additionally, the responsibilities andtiming may be clearly defined within the plan.

Subsequently, the team member may execute a “complete productionreadiness assessment” sub-activity. In exemplary embodiments, theexpectations associated with the sub-activity may indicate that thequality of the production trial run (pilot build) event may demonstratecomplete production readiness. Further, an event readiness assessmentmay be performed prior to the build(s) to indicate that the build(s) areexecuted with, production approved parts (PPAP or Interim-PPAP), and onproduction approved processes. Further, the control plans may beavailable and approved for usage by a responsible engineer.Additionally, production gauging may be available and approved forusage. Further, production packaging and logistics may be available forutilization during the build.

Subsequently, the team member may execute a “complete production trialrun (pilot build)” sub-activity. In exemplary embodiments, theexpectations associated with the sub-activity may indicate that theproduction trial run (pilot build) was completed as a coordinated event,utilizing the production facility, components, operators and logisticalsolutions. Further, the event met all expected quality targets and wasin-line with the NPI program timing.

In a further embodiment, the team member may be configured to execute apreliminary process capability study activity 254, as shown in FIG. 2.The activity 254 is a statistical assessment of the ability of theprocess to produce product within specification. Further, the teammember may execute a “verify process designs” sub-activity within theactivity 254. In exemplary embodiments, the expectations associated withthe sub-activity may specify a developed plan to complete preliminaryprocess capabilities studies including responsibility, timing andrequired actions. In one embodiment, all timing dates for each study maysupport GW6 requirements. Additionally, the plan may be communicated toa responsible party.

Subsequently, the team member may execute a “perform process capabilitystudy” sub-activity to indicate that a special characteristics (bothdesign & process related, which have been identified from theDFMEA/PFMEA) associated with the finished product/component maydemonstrate process capability under production conditions. In oneembodiment, the special characteristics (SCs) process capabilitiesindices may be greater than 1.67 Cpk/Ppk. However, in a furtherembodiment, the non-capable SCs having indices value of less than 1.67Cpk/Ppk may have specific additional controls added to the ProductionControl Plan, until the desired capability is demonstrated.

In a further embodiment, the team member may execute a productioncontrol plan activity 256, as shown in FIG. 2. The activity 256 mayindicate a written description of the systems for controlling parts andprocesses during full production. In one embodiment, the document isbased on the pre-launch control plan activity 244. Further, the teammember may execute a “develop manufacturing production control plans”sub-activity within the activity 256. In exemplary embodiments, theexpectations associated with the sub-activity may specify that aproduction control plan has been updated using the production trial run(pilot build) control plans with inputs from the items identified duringthe production trial run (pilot build) that need clarifications and/orconfirmation, inspection frequencies requiring modifications based offthe preliminary capabilities studies, and the lessons learnt during thedevelopment process.

Subsequently, the team member may execute a production validationtesting activity 258 to indicate a production control plan has beenupdated using the production trial run (pilot build) control plans withinputs from the items identified during the production trial run (pilotbuild) that need clarifications and/or confirmation, inspectionfrequencies requiring modifications based off the preliminarycapabilities studies, and the lessons learnt during the developmentprocess.

In one embodiment, the team member may execute a “develop manufacturingproduction test plan” sub-activity to indicate that a plan has beendeveloped to support the validation of the productioncomponents/assemblies, in conjunction with a finished product customer.Further, the validation process may be implemented in a number of forms,such as rig testing, in-application testing, CAE analysis, etc. As willbe understood, these are all acceptable forms of validations if thefinished product meets all the necessary technical objectives, and thecustomer approval. Further, the plan may detail, the target dates forthe completion of the various forms of validation. Additionally, theplan may be developed to support the validation of the productioncomponents and/or assemblies.

Subsequently, the team member may execute a “complete validation of theproduction components/assemblies” sub-activity within the activity 258.In exemplary embodiments, the sub-activity may indicate completion of avalidation testing on a finished product in accordance with a formallyagreed validation plan. Further, the results of these tests may beevaluated before releasing of the finished product for production byGW6.

In a further embodiment, the team member may execute an externalsupplier PPAP status activity 260. The activity 260 may identify andreport on the condition of an external supplier or a subcontractor'sPQPM process. Further, it is required that internal suppliers (withinthe organization) & external suppliers cascade PQPM requirements totheir sub-suppliers or sub-contractors, and conduct PQPM reviews asappropriate.

Further, the team member may execute a “develop (tier 1) supplier workplan to manage/monitor the development of components/systems”sub-activity within the activity 260. In exemplary embodiments, theexpectations associated with the sub-activity may specify that anoverall (tier 1) supplier work plan has been prepared to manage and/ormonitor the development of components and systems in support of the NPIprogram deliverables. In one embodiment, this may include a list ofsuppliers for all high risk systems and components and the responsibleteam leaders for each system and component. Further, the individualsupplier timing plans may support the delivery of PPAP at GW5 (pilotbuild) and may be confirmed by all interested parties.

Subsequently, the team member may execute a “complete reviews with(tier 1) suppliers on a regular basis in order to manage ongoing PQPMactivities” sub-activity. In exemplary embodiments, the expectationsassociated with the sub-activity may specify completion of the reviewswith (tier 1) suppliers on a regular basis in order to manage ongoingPQPM activities. Further, the team member may facilitate summaryreporting in order to demonstrate ongoing management of PQPM activitiesand status. Furthermore, open issues that may be identified in thedevelopment of high risk systems/components, may be documented toidentify responsible team leaders. Additionally, contingency plans maybe made available to mitigate the risk.

Subsequently, the team member may execute a “update supplier summary”sub-activity. In exemplary embodiments, the expectations associated withthe sub-activity may specify summary reporting in order to demonstrateongoing management of PQPM activities and status. Furthermore, openissues that may be identified in the development of high risksystems/components, may be documented to identify responsible teamleaders. Additionally, contingency plans may be made available tomitigate the risk.

Subsequently, the team member may execute a “gather review and approvePPAPs” sub-activity. In exemplary embodiments, the expectationsassociated with the sub-activity may specify receipt of a PartSubmission Warrant (PSW) from the 2nd tier supplier(s) to supportdelivery of material for the production trial run (pilot build).Further, the PSW may be accompanied with the PPAP information at theappropriate submission level.

In an embodiment, the team member may execute a PPAP Status activity 262to verify that the internal or external supplier meets all engineeringdesign requirements and their process has the capability to meet theserequirements during an actual production run at the quoted productionrate. Further, the team member may execute a “conduct PQPM riskassessment” sub-activity within the activity 262. In exemplaryembodiments, the sub-activity may indicate that the team may establishPPAP requirements for any prototype and/or pre-production and productionmaterial which will be supplied as part of the development process.Further, the team may confirm timing for these various PPAP submissionsagainst their Material Requirement Dates (MRD's).

Subsequently, the team member may execute a “submit Part SubmissionWarrant (PSW) to customers” sub-activity. In exemplary embodiments, thesub-activity may specify that a PSW is delivered to support delivery ofmaterial for the customers production trial run (pilot build and/orvalidation testing) and is accompanied with the PPAP information at theappropriate submission level.

Subsequently, the team member may execute a “production volumereadiness” sub-activity. In exemplary embodiments, the sub-activity mayspecify that the part and/or assembly is ready to support productionvolume. In one embodiment, the part and/or assembly may be ready oncethe customers production trial run (pilot build) and subsequentvalidation testing are completed.

Referring to FIG. 3, an exemplary implementation of the GUI module 110is depicted, according to an embodiment of the disclosure. Asillustrated in FIG. 3, the GUI module 110 may be deployed on the server102 and is communicatively coupled to the repository 104, and the userdevice 106. In an embodiment, the GUI module 110 may enable a teammember to facilitate the PQPM project on the user interface 112. The GUImodule 110 may include a display module 302, a receiving module 304, atracking module 306, and a developing module 308.

In an embodiment, the display module 302 is configured to provide a pathon the user interface 112 to create a new PQPM project. In oneembodiment, a PQPM project may involve one or more team members forcompletion of various activities and sub-activities associated with thePQPM project. A team member having valid login credentials may create anew PQPM project. In an embodiment, the team member who creates the PQPMproject is by default set as the team leader for the PQPM project.Examples of the team members may include a design engineer, a designteam lead, a (New Product introduction) NPI team lead, an NPI engineer,a process control engineer, a quality engineer, a validation engineeretc. As illustrated in FIG. 4, the display module 302 may provide a userinterface window 400 to enable the team leader to create a new PQPMproject.

The user interface window 400 may include a “+New Project” tab tofacilitate creation of the PQPM project. As illustrated in FIG. 5, thedisplay module 302 may subsequently provide a user interface window 500for providing information associated with the PQPM project. Further, thereceiving module 304 may receive a plurality of required informationfrom the team leader to successfully create the PQPM project. In oneembodiment, the required information may include basic key informationsuch as project title, project class, project type, project creationdate, start date, etc. Further, the required information may includeadditional information such as a one or more associated (New productinformation) NPI programs, Part information, supplier information etc.On successfully receiving the required information from the team leader,the GUI module 110 may assign a PQPM project number to the newly createdPQPM project. In one embodiment, the display module 302 may beconfigured to display a notification message to the team leader if theentered information is stored for a previously existing PQPM project.Subsequently, the GUI module 302 may create a hyperlink to thepreviously stored PQPM project.

On successful creation of the new PQPM project, the display module 302may be configured to provide a user interface window 600 under“Information” sub tab, in the “Overview” tab, as illustrated in FIG. 6.The window 600 includes information related to the newly created PQPMproject. Further, the information related to the PQPM project mayinclude a PQPM project id, project name, project title, project creationdate, project start date etc. Further, the user interface window 600 mayinclude an “Edit” tab to facilitate the team leader to edit theinformation associated with the PQPM project. Further, on clicking the“Edit” tab in the user interface window 600, the display module 302 maydisplay a user interface window 700 to facilitate the team leader to addadditional information associated with the newly created PQPM project.In one embodiment, the additional information may include partinformation, supplier information, associated NPI project etc.

Subsequently, the receiving module 304 may receive part informationassociated with the PQPM project, from the team leader. In oneembodiment, the team leader may import part information from an(Engineering Data Systems) EDS database by clicking on an “+Add EDS” tabdisplayed in the user interface window 700. In an alternate embodiment,the team leader may also import part information from a team centerengineering database by clicking on an “+Add Team Center Engineering”tab displayed on the user interface window 700. In another embodiment,the team leader may manually enter the part information if the partinformation is not available in both the EDS database and the teamcenter engineering database. In various embodiments of the disclosure,the databases such as the EDS database, and the team center engineeringdatabase may be part of the repository 104 as explained in FIG. 1.

As illustrated in FIG. 8, on clicking the “+Add EDS” tab, the displaymodule 302 may provide an “EDS part Search” user interface window 800 tothe team leader for searching and adding the part information related tothe PQPM project. For example, the team member may search the partinformation in the EDS database by clicking on one of a “Part NumberSearch” and a “Part Name Search” options provided on the user interfacewindow 800. In one embodiment, the GUI module 110 may subsequentlyextract the relevant part numbers and part names from the EDS databasebased on the team leader's selection. In one embodiment, the team leadermay highlight the desired part information and click on an “OK” buttonin the user interface window 800. Subsequently, the selected partinformation is added to the PQPM project.

In an alternate embodiment, the team leader may click on the “+Add TeamCenter Engineering” in the user interface window 700 to import the partinformation from the team center engineering database. Further, thedisplay module 302 may provide a “Team center Part Search” userinterface window 900 for searching the part information from the teamcenter engineering database, as illustrated in FIG. 9. For example, theuser interface window 900 may include a “Design Facility” tab, tofacilitate the team leader to select a design facility, for importingthe part information. Subsequently, the team leader may select the “PartNumber Search” or “Part Name search” for searching the desired partinformation. In a further embodiment, the team leader may enter the partnumber or a keyword including the desired part name to be searched inthe user interface window 900. Subsequently, the GUI module 110 mayextract all the relevant part information based on the part number andthe part name entered by the team leader. The team leader maysubsequently select the desired part information to be added to the PQPMproject.

In an embodiment, the display module 302 also provides a path in theuser interface 112 for adding supplier information. As will beunderstood by a person having ordinary skill in the art, a supplier maybe an external person or a party for supplying parts to the organizationhosting the PQPM project. In one embodiment, a supplier team may bedivided into various levels of hierarchy, such as supplier qualitycontact, supplier design engineer, supplier accounting contact, suppliermanager etc.

In one embodiment, the user interface window 700 may include a “+Add”tab adjacent to the supplier information. Subsequent to clicking on the“+Add” tab, the display module 302 may be configured to display a“Supplier Search” user interface window 1000 for facilitating the teamleader to add the supplier information to the PQPM project, asillustrated in FIG. 10. In one embodiment, the supplier information maybe imported from an external database. For example, the team leader maysearch supplier information using one of a supplier code or a suppliername. Further, the team leader may enter a desired supplier name or asupplier code in the user interface window 1000. Subsequently, the GUImodule 110 may extract and list all the relevant supplier informationfrom the external database. Furthermore, the team leader may select thedesired supplier information from the list provided on the userinterface window 1000, to add the supplier to the PQPM project.

As illustrated in FIG. 11, the display module 302 may be configured todisplay a user interface window 1100 to facilitate the team leader toassociated New Product Introduction (NPI) programs with the PQPMproject. As will be understood by a person having ordinary skill in theart, an NPI program may be defined for an entire product developmentlifecycle. An NPI program may include various parts and for every part,a new PQPM project may be created. In one embodiment, a PQPM project maybe a subset of an NPI program.

In one embodiment, the user interface window 1100 may be accessed byclicking on a “+Add associated NPI programs” tab displayed on the userinterface window 700. The NPI database, which may be a part ofrepository 104 or an external database, may store the NPI programworkflow tool, defining the workflow for development of a new product.The display module 302 is further configured to facilitate the teamleader to search a related NPI program based on one of an NPI programcode and/or an NPI program name. In one embodiment, the team leader mayselect one of “Program Number” or “Program code” in the user interfacewindow 1100 for searching the NPI programs. Subsequently, the receivingmodule 304 may receive textual inputs in the form of the Program number,keywords or codes as desired, for searching the relevant NPI programs.Further, the display module 302 may extract and list all the relevantNPI programs available based on the entered keyword or the code.Furthermore, the team leader may select the desired NPI program to beadded to the PQPM project. Once the team member clicks on an “OK” tab onthe user interface window 1100, the GUI module 110 may add the selectedNPI program to the PQPM project.

In one embodiment, on successful addition of the associated NPI program,the GUI module 110 may be configured to automatically extract relevantcorresponding gateway dates to be associated with the PQPM project andits activities and sub-activities. For example, the gateway dates may bein a standard MM-DD-YYYY format. In one embodiment, the gateways may bethe predefined process milestones and phases to be completed during theentire product development lifecycle. For example, the entire productdevelopment lifecycle in an NPI program workflow may be divided into 8phases. The phases may be strategy, Concept define, Concept measure,Concept Explore, develop design, develop verify, Pilot, and a productionphase. In one embodiment, every phase in the NPI workflow may includeone or more activities and sub-activities to be executed in that phase.In a further embodiment, at the end of every phase, a gateway review maybe conducted by an NPI team, to assess whether an acceptable level ofprogress has been achieved in that phase. Therefore, the gateway datesmay be understood as the target dates for completing the phase and thecorresponding gateway review.

In one embodiment, the display module 302 is further configured toprovide a path on the user interface window 700 to view and add relevantgateway dates for the various parts associated with the selected NPIprogram. For example, once the team leader selects the relevant NPIprogram from the list of NPI programs presented on the user interfacewindow, the display module 302 may further display all the gateway datesassociated with the selected NPI program on a user interface window1200, as illustrated in FIG. 12. In one embodiment, the gateway datesmay be populated for the selected NPI program, and subsequently beselected as the required program dates for the PQPM project. In oneembodiment, the gateway dates may also be stored in the NPI database.

In an embodiment, the display module 302 may be configured to facilitatethe team leader and/or an administrator for manual editing of thepreviously stored gateway dates associated with the PQPM project.However, it will be appreciated, that once the previously associatedgateway dates are modified, the corresponding previously associated NPIproject may be delinked from the PQPM project automatically by the GUImodule 110. Furthermore, at the time of subsequent login by the teamleader, the display module 302 may display a notification message forthe changed gateway dates. In another embodiment, the team leader mayalso sync the gateway dates with the associated NPI program gatewaydates. The display module 302 may be configured to facilitate the teamleader and/or the administrator to view an entire history of the changesmade to the gateway dates of the PQPM project.

Further, the team leader may select more than one NPI programs to beadded to the PQPM project. For example, a single part for which the PQPMmay be conducted, may be a part of more than one product, therefore,there may be more than one NPI programs to be associated with the PQPMproject. Subsequently, the display module 302 may be configured tofacilitate the team leader to select one of the associated NPI projectsfor selecting the relevant gateway dates for the PQPM project. In anembodiment, the system 100 may automatically select the date of theearliest NPI program for selecting the relevant gateway dates for thePQPM project. Further, the display module 302 is configured tofacilitate addition of one or more NPI projects at any later stage ofthe PQPM project. It will be understood by a person having ordinaryskill in the art, that if the gateway dates of the newly added NPIproject are earlier than the previously added NPI project, then thesystem may notify the team leader to change the gateway dates of thePQPM project according to the gateway dates of the newly added NPIprogram. Once the team leader confirms, the system may update thegateway dates of the PQPM project accordingly. However, the team leadermay also reject the changes in the gateway dates based on the newlyadded NPI programs and retain the gateway dates associated with thepreviously associated NPI program.

Once the entire PQPM project is created, the GUI module 110 may providea path to create an initial session associated with the PQPM project.For example, the initial session may not have any attendees, and may beof zero hour duration. In one embodiment, the display module 302 isfurther configured to facilitate the team leader in adding a session atany later stage of the PQPM project. For example, the user interfacewindow 600 may include a “Sessions” tab to facilitate the team leader inadding or removing a one or more sessions to the PQPM project.Subsequent to clicking the “Sessions” tab, the display module 110 may beconfigured to display a session user interface window 1300, asillustrated in FIG. 13. In one embodiment, the team leader may click ona “+Add Session” tab to enable the receiving module 304 to receivetextual inputs from the team leader, for the information associated withthe session. For example, the information may include a session title,session date, attendees, duration of the session, minutes of the meetingdocument etc. In one embodiment, the attendees may be selected from alist of team members displayed to the team leader on the user interface112. In an alternate embodiment, if an attendee is not included in thelist of the team members, then the team leader may add notes to thesession to indicate the name of the attendee.

Once the PQPM project is created successfully, the display module 302 isconfigured to facilitate a team leader, and/or a project administratorto view a “Summary” tab on the user interface window 1400 to view thevarious activities and sub-activities associated with the PQPM project.In one embodiment, the “Summary” tab on the user interface window 1400may include the project id, project title, team leader, the PQPMactivities to be executed, the relevant NPI gateways along with thegateway dates, gateway scores, total gateway scores, percentage gatewayscores etc. As will be understood, the gateway scores may indicate theexecution status of the PQPM activities and sub-activities. In anembodiment, the team member may select to view either both theactivities and the sub-activities in the “Summary” tab or only theactivities by collapsing the sub-activities under the correspondingactivities, as illustrated in a user interface window 1500 of FIG. 15.

In an embodiment, as illustrated in FIGS. 14 and 15, only the gatewaysrelevant to the activities and the corresponding sub-activities may beaccessible on the summary page and rest of the gateways arenon-accessible. Also, gateways for a particular activity may be based onthe gateways associated with sub-activities within the activity. Forexample, for activity 3, the display module 302 may be configured tohighlight all the gateways associated with the sub-activities within theactivity 3 in the “Summary” page. In one embodiment, the activity 3 mayinclude sub-activity 3.1, sub-activity 3.2, sub-activity 3.3 andsub-activity 3.4. Further, sub-activity 3.1 may be associated withgateway 2, sub-activity 3.2 may be associated with gateway 3,sub-activity 3.3 may be associated with gateway 4, and sub-activity 3.4may be associated with gateway 5. Therefore, in the user interfacewindow 1500, the gateways 2, 3, 4 and 5 may all be highlighted for theactivity 3.

Further, the display module 302 may provide a path to the team leaderthrough the user interface window 600 for adding various team member,assigning sub-activities to the team members and related information tothe PQPM project. In one exemplary embodiment, team member informationmay be stored in a global directory of the organization that may includeall the information about each employee of the organization across theglobe. However, in an alternate embodiment, the team leader may searchthe team member from an address book associated with the team leader.

In an exemplary embodiment, the team leader may click on a “+Add TeamMember” tab under the “Team” tab displayed on the user interface window600 to search team members to be added to the PQPM project.Subsequently, as illustrated in FIG. 16, the display module 302 may beconfigured to display a user interface window 1600 for adding the teammember from either the global directory or the address book of the teamleader. In one embodiment, the team leader may click on the “+Add teammember” tab to search team members from the global directory of theorganization. In a further embodiment, the display module 302 may beconfigured to display a “Search Team Members” user interface window 1700for adding the team member to the PQPM project, as illustrated in FIG.17. The user interface window 1700 may include a plurality of optionsfor searching the team members in the directory. For example, the userinterface window 1700 may facilitate the team leader to search the teammembers by names, or employee ids, or login ids etc. As illustrated inFIG. 17 the receiving module 304 may receive the keywords from the teamleader for searching the team members. In one embodiment, the displaymodule 302 may subsequently display a list of all the relevant teammembers, on the user interface window 1700, based on the searchkeywords. Subsequently, the team leader may select the desired teammember to be added to the PQPM project. The display module 302 maydisplay the selected team member's information in the “Team” tab of thePQPM project.

In an alternate embodiment, the team leader may search his/her addressbook for adding a team member to the PQPM project. For example, the teamleader may click on “+Add From Address Book” tab under the “Team” tab,as illustrated in FIG. 16. In an embodiment, the display module 302 maybe configured to provide a path to the team leader on the user interfacewindow 1600, for searching and adding a team member to the PQPM projectfrom the address book. Further, the display module 302 may provide theuser interface window 1600 including the address book of the teamleader. Subsequently, the team leader may select the desired team memberto be added to the PQPM project.

Subsequently, as illustrated in FIG. 18, the display module 302facilitates the team leader through a user interface window 1800 inassigning one or more desired sub-activities to the team membersassociated with the PQPM project. As will be understood by a personskilled in the art, only a team leader may assign a role along with thesub-activities to a team member in the PQPM project. For example, theuser interface may facilitate the team leader to select a desired teammember in the “Team” tab and subsequently select the desiredsub-activities, from a list of sub-activities displayed on the userinterface, to be assigned to the team member. In one embodiment, theteam leader may select more than one sub-activities presented on theuser interface window 1800 to be assigned to the selected team member,as shown in FIG. 18. In one embodiment, the team leader may assign rolebased access to the various team member associated with the PQPMproject. In a further embodiment, the team leader may change the teammember's role and the assigned sub-activities at any time during thePQPM project. In an embodiment, the team member is provided a role basedaccess control in the PQPM project.

Further, the team leader may also delete a team member from the PQPMproject. In one embodiment, the display module 302 may display anotification to the team leader, if a team member has been assigned anysub-activities, before the team leader deletes the team member from thePQPM project.

As illustrated in FIG. 19, the display module 302 may be configured tofacilitate the team member to view and edit the detailed informationassociated with every activity and sub-activity of the PQPM project. Forexample, the team leader may click on a “Details” tab on the userinterface window 600, to view the detailed information associated withthe activities and the sub-activities associated with the PQPM project.As illustrated in FIG. 19, the “Details” tab may include a firstnavigation panel 1902 listing the activities and the associatedsub-activities. In one embodiment, the activities and the correspondingsub-activities may be arranged in a tree structure organization in thefirst navigation panel 1902. In one embodiment, a team member may clickon a desired activity to view an information page 1904 associated withthe activity. For example, the information related to the activity mayinclude but not limited to, the definition of the activity, theassociated sub-activities, the associated gateways with thesub-activities, and the status of the sub-activities. Additionally, theteam member may also add notes related to the activity for futurereferences.

Further, the display module 302 is configured to facilitate the teammember in viewing the details associated with each sub-activity withinthe activities. In one embodiment, the user interface window 1900 mayenable the team member to view the details associated with thesub-activity by double clicking on the sub-activity in the treestructure displayed on the first navigation panel 1902. In a furtherembodiment, the display module 302 is configured to provide a path forviewing the detailed information associated with the sub-activities on auser interface window 2000, as illustrated in FIG. 20. In oneembodiment, the user interface window 2000 may include an informationpage 2004 associated with the selected sub-activity. For example, theinformation page 2004 may include a plurality of pre-defined informationassociated with the sub-activity, such as an associated gateway, therequired date, gateway start date, gateway target date, the team memberresponsible for performing the activity, etc.

Further, the user interface window 2000 may enable the receiving module304 to receive the measurement criterion associated with an executionstatus of the sub-activities corresponding to the activities. Themeasurement criterion is based on a forecast execution and an assessmentof reaching an expectation associated with the sub-activities. Further,the measurement criterion for the forecasted execution is based on firstpre-determined scoring rates. The first pre-determined scoring rates isfurther based on a probability of meeting a specified target date, aspecified quality level and a cost expectation associated with thesub-activity. Similarly, the measurement criterion for the assessment isbased on second pre-determined scoring rates. However, the receivingmodule 304 may only receive the measurement criterion for the assessmentonly if the forecasted execution is marked as completed.

In an embodiment, the associated gateway may have a gateway indicatorvisually representing the measurement criterion or an execution statusof the sub-activity. The gateway indicator is based at least on eitherthe first pre-determined scoring rate associated with the forecastedexecution or the second pre-determined scoring rate associated with theassessment. In an exemplary embodiment, the gateway indicator may bevisually represented using color coding, number coding, letter coding,hatch patterns, alphanumeric coding or a combination thereof.

In one embodiment, the receiving module 304 may be configured to receivethe forecast value from the team member, based on a forecasted executionstatus of the sub-activity. As illustrated in FIG. 20, the displaymodule 302 is configured to display a “Forecast” dropdown tab on theuser interface window 2000, to facilitate the team member in selecting adesired forecast value for the sub-activity, based on the firstpre-determined scoring rates. At the time of creation of the PQPMproject, the forecast value is not marked. Subsequently, the team membermay update the value of the forecast, based on the forecasted executionof the sub-activity. For example, if the sub-activity is not to beconsidered for forecast, then the team member may mark “N/A” in the“Forecast” dropdown tab. In a further example, the team member may mark“0” in the “Forecast” tab, if the sub-activity cannot meet the specifiedtarget dates, the specified quality level and cost expectations.

Subsequently, as illustrated in FIG. 20, the display module 302 may beconfigured to update the gateway indicator, such as with a red color ora first hatch pattern, for “0” forecast value. The red color or thefirst hatch pattern may indicate a high risk associated with thesub-activity and that an immediate program management action needs to beimplemented.

In another exemplary embodiment, the team member may mark the “Forecast”tab as “3”, if there is a possibility that the planned sub-activity maynot meet the target dates, the specified quality level and costexpectations. Further, as illustrated in FIG. 21, the display module 302may be configured to update the gateway indicator, such as with yellowcolor or a second hatch pattern. The yellow color or the second hatchpattern may indicate a medium risk associated with the sub-activity, andthat a program management monitoring is required for the sub-activity.In a further embodiment, the team member may mark the “Forecast” tab as“9”, if the planned activity will most probably meet the target dates,the specified quality levels as well as the cost expectations.Subsequently, as illustrated in FIG. 22, the display module 302 may beconfigured to update the gateway indicator, such as with green color ora third hatch pattern, to indicate a low risk associated with thesub-activity.

In another embodiment, the team member may mark the “Forecast” tab as“Complete”, if the execution of the sub-activity is completed. Once the“Forecast” tab is marked complete, then the team member may provide theassessment of the sub-activity. In one embodiment, the display module302 may be configured to enable the team member to provide assessment ofthe sub-activity through a user interface window 2300, as illustrated inFIG. 23. For example, an “Assessment” dropdown tab is enabled forediting, to further facilitate the team member to enter the assessmentvalue for the sub-activity.

In one embodiment, if a detailed profile or a substantial amount ofprofile information for the finished product is not available for teamreference, then the team member may mark the “Assessment” tab as “0”.Subsequently, as illustrated in FIG. 23, the display module 302 mayupdate the gateway indicator with a red color or the first hatch patternalong with a “C” mark. The “C” mark may indicate that the sub-activityis completed, however, the red color may indicate that the detailedvolume profile of the sub-activity is not available for team reference.

In another embodiment, the team member may mark the “Assessment” tab as“9”, if the detailed volume profile and the maximum capacity planningvolume for the finished product is available for team reference.Subsequently, as illustrated in FIG. 24, the display module 302 mayupdate the gateway indicator with a green color or the third hatchpattern along with the “C” mark. As will be understood by a personhaving ordinary skill in the art, the “C” mark may indicate that thesub-activity is completed, and the green color or the third hatchpattern may indicate that the detailed volume profile of the finishedproduct is available for team reference. In one embodiment, the displaymodule 302 may be configured to display an entire history of changesmade to the gateway indicators for every sub-activity within the PQPMproject.

In a further embodiment, the display module 302 may be configured toupdate the information page 2004 in the user interface 112 to displaythe assessment information available for the selected assessment valuefor each sub-activity in the PQPM project. For example, the assessmentinformation may be based on the predefined expectations of thesub-activity, as well as the assessment value entered by the teammember. As will be understood by a person having ordinary skill in theart, the assessment information may be varied based on the associatedsub-activity, the associated assessment value and the associatedexpectations with the sub-activity. In a further embodiment, theassessment information for every sub-activity may be stored in therepository 104, accessible by the entire PQPM team.

In a further embodiment, the team leader may add team member toindividual sub-activities. In one embodiment, the display module 302 mayprovide a path on the user interface 112, through the “Details” tab, foradding team members individually to every sub-activity. For example, theinformation page 2004 within the user interface window 2000 includes an“Assign User” tab for adding a team member to the sub-activity. Once theteam leader clicks on the “Assign user” tab, the display module 302 maysubsequently display a list of available team members for the PQPMproject. In one embodiment, the display module 302 may display theaddress book associated with the team leader. In an alternateembodiment, the display module 302 may display the global directory ofthe employees within the organization. Subsequently, the team leader mayselect the desired team member to be assigned to the sub-activity.

Further, for every incomplete sub-activity, the team member may add oneor more issues related to the execution of the sub-activity. In oneembodiment, the information page 2004 may include a “+Add issue” tab, tofacilitate the team member to add issues related to the execution of thesub-activity. Subsequently, the receiving module 304 may receiveinformation related to the issue to be added to the sub-activity. In oneembodiment, the information related to the issue may include an issuedescription for red or yellow gateway indicators, corrective actions andresolution plans, timing of the issue and the responsible team memberfor resolving the issue. Subsequently, on clicking an “OK” button, theissue may be added to the sub-activity. In an alternate embodiment, theteam member may add an issue to a sub-activity by clicking on an “Issue”tab on the home page displayed on the user interface 400, as illustratedin FIG. 4. Subsequently, the display module 302 may enable the teammember to add issue through a user interface window 2500, as illustratedin FIG. 25. Subsequently, the receiving module 304 may receive textualinputs from the team member, for one or more information related to theissue. In a one embodiment, the team member may select the sub-activityfrom a drop-down tab as displayed on the user interface window 2500. Inone embodiment, the team member may enter additional information relatedto the issue, such as open date of the issue, end date of the issue,required date, status of the issue, responsible team member and the roleof the team member. Further, as the team member clicks on the “SAVE”button, the display module 302 adds the issue to the sub-activity. Aswill be understood by a person ordinarily skilled in the art, the teammember may edit or delete the issue at any stage of the PQPM project.Further, the GUI module 110 may be configured to facilitate the teammember to export all the issues associated with the PQPM project to anexcel file. In one embodiment, the user interface window 2500 mayinclude an “Export” tab, to enable a team member to export the issues toan excel file.

Further, the display module 302 may be configured to provide a path tothe team member, through a user interface window 2600, for adding anattachment related to the sub-activity, as illustrated in FIG. 26.Further, the display module 302 may enable the team member to link theattachments to one or more sub-activities. For example, the team membermay attach an instruction file to execute a sub-activity. Further, theuser interface 2600 may include a “+Add attachment” tab for adding anattachment. Further, the team member may click on a “Browse” button tobrowse the local system of the team member for uploading the attachmentto the PQPM project.

Once the attachment is added to the PQPM project in the “Attachment”tab, then subsequently, the team member may link the uploaded attachmentto one or more sub-activities. For example, the team member may click onthe sub-activity in the first navigation panel 1902 on the “Details”tab, as illustrated in FIG. 19. Subsequently, the information page 2004may include a “Link Attachment” tab, to facilitate linking of one of theattachments to the sub-activity. Further, the display module 302 maylink the selected attachment to the sub-activity. As will be understoodby a person ordinarily skilled in the art, the attachments may be editedor deleted by the team member at any stage during the PQPM project.

In an embodiment, the display module 302 may be further configured toupdate the “Summary” tab on the user interface window 2700, asillustrated in FIG. 27, based on the received textual inputs formeasurement criterion associated with the execution status ofsub-activities. For example, the “Summary” tab may include the gatewayindicators as illustrated in the “Details” tab of the PQPM project. Inan exemplary embodiment, the PQPM activities and sub-activities may bedisplayed in a first navigation panel 2702 on the user interface window2700 as illustrated in FIG. 27. In an exemplary embodiment, the displaymodule 302 may be configured to display the relevant gateways in asecond navigation panel 2704 besides the first navigation panel 2702.For example, the relevant gateways in the second navigation panel 2704may be indicated in similar manner as the gateway indicators in the“Details” tab for every sub-activity in the PQPM project. In a furtherembodiment, for every sub-activity for which the gateway indicator inthe “Details” tab is not updated, the gateway indicator in the secondpanel 2704 in the “Summary” tab may not be highlighted. As will beunderstood by a person having ordinary skill the art, the display module302 may update the non-highlighted gateway indicators on the secondpanel 2704 on the “Summary” tab, based on the updates in thecorresponding gateway indicators in the “Details” tab. For example,initially, when the sub-activity is not executed, the relevant gatewayindicator on the second panel 2704 in the “Summary” tab may not behighlighted. In a further example, the display module 302 may update thegateway indicator on the second panel 1704, based on the updates in thecorresponding gateway indicator in the “Details” tab of thecorresponding sub-activity. For example, on completion of thesub-activity, and based on the forecast and the assessment value of thatsub-activity in the “Details” tab, the gateway indicator in the secondpanel 2704 of the “Summary” tab may be updated to red, yellow or greencolor, or with the “C” indicator along with different color coding orhatch pattern.

In an embodiment, for all the activities, the second navigation panel2704 may include all the gateway indicators relevant to thecorresponding sub-activities within the activity. For example, for theactivity 16 “packaging specifications”, the second navigation panel 2704may include all the gateways related to all the sub-activities withinthe activity 16. In a further embodiment, the gateways that are notrelevant to a sub-activity may be non-accessible or darkened orblackened.

Further, as illustrated in FIG. 27, the second panel 2704 may include asummary status indicator for each activity and sub-activity. In oneembodiment, the display module 302 may be configured to update thesummary status indicator based on the forecast and the assessment valueassociated with the sub-activities within an activity. In a furtherembodiment, the summary status indicator for an activity indicates theoverall execution status of the activity. For example, if all thesub-activities within the activity are completed with the assessmentvalue 9, i.e., the third hatch pattern or green color with “C” mark,then only the summary status indicator for the activity indicates Greenor third hatch pattern along with “C” mark. As will be understood by aperson skilled in the art, Green or third hatch pattern with “C”indicates that the activity is completed with the desired target date,quality level and cost expectations. However, if even a singlesub-activity within the activity is incomplete, then the summary statusof the activity indicates the lowest execution status and/or the highestrisk status associated with the sub-activity. As shown in FIG. 27, forsub-activity 16.1, the gateway indicator shows that the sub-activity iscompleted with desired target date, quality level and cost expectations,therefore indicator with green or third hatch pattern with “C” mark.Further, for sub-activity 16.2, the gateway indicator shows that thesub-activity has a forecast value of 9, therefore green or third hatchpattern. For sub-activity 16.3, the gateway indicator shows that thesub-activity is completed with an assessment value of 0, which meansthat there is risk associated with the sub-activity, therefore indicatorwith red or first hatch pattern with “C” mark. Furthermore, forsub-activity 16.4, the gateway indicator shows that the sub-activity hasa forecast value of 3, which means that the sub-activity may not becompleted with the desired target date, quality level and costexpectations, therefore indicator with yellow or second hatch pattern.Therefore, the summary status indicator for the activity 16 may indicatea red or first hatch pattern showing that the activity on a whole is notcompleted and has a risk associated with it.

Further, the display module 302 may provide a path through the “Summary”tab, to enable the team member to update the forecast and the assessmentvalues associated with each sub-activities. For example, the team membermay click on the gateway indicator displayed on the second navigationpanel 2704 to update the forecast and the assessment values associatedwith the sub-activity. In one embodiment, the gateway indicator on thesecond panel 2704 may be updated to reflect the updated assessment andforecast values of the sub-activity.

In an embodiment, the tracking module 306 may enable the teammembers/team leader to track a progress of the PQPM project based on thereceived textual inputs for the measurement criterion associated withthe execution of the activities. The tracking module 306 may provide a“total possible gateway score” and a “gateway score” in the “Summary”tab on the user interface window 2700. In one embodiment, the “totalpossible gateway score” may be the total score possible for everygateway. For example, the “total possible gateway score” may bedetermined by identifying the total number of sub-activities relevant tothat gateway and taking a product of the total number with the highestassessment value, i.e., 9. For example, if the total number ofsub-activities relevant to a gateway, such as gateway 2, is equal to 12,then the total possible gateway scores is the product of 12 and 9, i.e.,108.

In a further embodiment, the display module 302 may be configured todisplay the gateway score associated with every gateway. The gatewayscore may be based on the number of completed sub-activities with thedesired target dates, quality levels and cost expectations, i.e., allthe sub-activities with Green or third hatch pattern along with “C”mark, relevant to the particular gateway. For example, if for a gateway,such as gateway 3, the total number of sub-activities is 15, and out of15 sub-activities, only 8 are completed with the desired target date,quality level and the cost expectations, then only the completedsub-activities may be considered for evaluating the gateway score in asimilar manner as done for total possible gateway score. Therefore, inthe above example, the gateway score may be equal to the product of 8and 9, i.e. 72.

In a further embodiment, the display module 302 may evaluate thepercentage of gateway score by comparing the total possible gatewayscore and the gateway score. In a further embodiment, the GUI module 110may also evaluate a cumulative PQPM project status percentage score forthe entire project to enable the team member to evaluate the totalpercentage of the completed PQPM project. In one embodiment, thecumulative score for every gateway may be evaluated by a formula of(cumulative gateway score for a gateway)/(cumulative total possiblegateway score)*100. For example, for gateway 1, the cumulative totalpossible score is 0 and the cumulative gateway score is also 0,therefore the cumulative PQPM status percentage score is also 0.Further, for gateway 2, the cumulative total possible gateway score is asum of 108 and 0, i.e., 108, and the cumulative gateway score is the sumof 54 and 0, i.e., 54. Therefore the cumulative PQPM status percentagescore for gateway 2 is 54/108*100, i.e., 50%. Similarly, the cumulativetotal possible gateway score is the sum of 108, 162, 108 and 0, i.e.,378, and the cumulative gateway score is the sum of 9, 27, 54 and 0,i.e., 90. Therefore, the cumulative PQPM status percentage score forgateway 4 is 90/378*100, i.e., 23.81%. Similarly, the display module 302may be configured to display the cumulative PQPM project statuspercentage score for every gateway, to enable the team member to track aprogress of the PQPM project based on the execution status of the PQPMproject.

In one embodiment, the display module 302 may display a visual indicatoralong with an activity and associated sub-activities in the firstnavigation panel 2702, to indicate a linkage of the activity andassociated sub-activities with another PQPM project (herein afterreferred to as parent PQPM project). In one embodiment, sub-activitieswithin the activity may include similar execution characteristics withanother PQPM project. Therefore, the execution of the sub-activitywithin the PQPM project may be linked to the parent PQPM project. Aswill be understood by a person skilled in the art, for similar parts,the sub-activities and activities execution characteristics may besimilar, therefore, one of the PQPM project may be made a parent projectand the sub-activities that are common to the child project may belinked.

In one embodiment, a team leader may link activities to a parent PQPMproject. For example, if a sub-activity is executed for a parent PQPMproject, then the GUI module 110 automatically updates the executionstatus of the child PQPM projects similar to the execution status in theparent PQPM project. In an embodiment, the user interface window 600 mayinclude a “Parent Project” tab, to facilitate the team leader to linkactivities of the PQPM project with the parent PQPM project. The teamleader may click on the “Parent Project” tab to subsequently add aparent PQPM project for the PQPM project. The display module 302 may beconfigured to display a “Parent Project” user interface window 2800 tofacilitate addition of a parent PQPM project and linking of activitiesto the parent PQPM project. For example, the user interface window 2800may include an “Edit” button to facilitate searching of a PQPM projectto be added as a parent PQPM project. As illustrated in FIG. 29, thedisplay module 302 may be configured to display a user interface window2900 to facilitate searching of the PQPM projects by the project titleand/or a project id. Further, the display module 302 may display a listof all the related PQPM projects based on the keywords. Subsequently,the team leader may select the desired PQPM project to be added as theparent PQPM project. Further, as illustrated in FIG. 30, the team leadermay select activities to be linked to the parent PQPM project, throughthe user interface window 3000.

In a further embodiment, the display module 302 may provide a path tothe team members to view the PQPM projects assigned to them in a “MyProjects” tab on the Home page in a user interface window 3100, asillustrated in FIG. 31. The display module 302 may further facilitatethe team leader and/or any other team member to navigate the PQPMproject through the user interface window 3100 to view the informationassociated with the PQPM project. For example, the team member maynavigate the PQPM project through the user interface window 3100 bydouble clicking on the desired PQPM project.

In a further embodiment, the display module 302 may provide a path onthe user interface 112 to the team member for viewing all thesub-activities assigned to him/her through a “My Action Items” tabdisplayed on a user interface window 3200, as shown in FIG. 32. In oneembodiment, the window 3200 may include information associated with thevarious sub-activities associated with the team member. For example, theinformation may include the project id of the PQPM project, suppliername associated with the project, sub-activity number, description ofthe sub-activity and the corresponding activity, and the desired targetdate for completing the sub-activity. In one embodiment, the GUI module110 may also send alerts to the team member on arrival of a target forcompleting the sub-activity. In another embodiment, the team member maydefine alert preferences in the user interface 112 for receiving alertsnear to a target date for any of the assigned sub-activities.

In an embodiment, the developing module 306 may be configured togenerate risk charts and reports for the PQPM project and associated NPIprograms. The reports are developed based on the measurement criterionindicative of the execution status of the activities. Thus, the reportsmay enable the team members to monitor the risk associated with thevarious activities and sub-activities within the PQPM project andfurther within the NPI program.

In an embodiment, the developing module 306 may develop four types ofreports, namely, an NPI project report for PQPM conformance, an NPIprogram view report, a PQPM risk report and a PQPM NPI gatewayconformance report. However, it will be understood by a personordinarily skilled in the art, that the number of reports and the typesof the reports are exemplary and may be varied to include similarfunctionalities.

In an embodiment, the developing module 306 may develop the NPI projectreport for PQPM conformance, to facilitate the team member to view allthe PQPM projects within an NPI program and the risk associated withevery PQPM project within the NPI program. The display module 302 mayprovide a path to the team member through a user interface window 3300to get the NPI program view report. For example, the user interfacewindow 3300 may include an “NPI project reports” tab, as illustrated inFIG. 33, to enable the receiving module 304 to receive NPI program IDand a gateway number as a search term from the team member.Subsequently, the team member may click on a “Get Report” tab to viewall the APQP projects and the risk associated with the APQP projectswithin the NPI project.

In an embodiment, the display module 302 may display the NPI projectreport for PQPM conformance in a user interface 3400, as illustrated inFIG. 34. As will be understood by a person having ordinary skill in theart, the NPI project report for PQPM conformance may illustrate all thePQPM projects within the selected NPI project. Further, the report mayillustrate the risk associated with the APQP projects within the NPIprogram. In one embodiment, the NPI projects report for APQP conformanceas shown in FIG. 34, may include a bar chart for illustrating the numberof PQPM projects within the NPI program that may be categorized intodifferent categories of risk associated with the projects. For example,the categories may A-category, B-category, C-category and D-category. Inone embodiment, the A-category risk is the highest risk and requireshighest amount of supply chain, and D is the lowest risk associated withthe APQP project and requires the least amount of supply chaincollaboration.

Further, the report on the user interface 3400, may include a second barchart illustrating the total number of projects showing completed PQPMprojects and their status with respect to meeting desired target dates,quality levels and the cost expectations, along with number of PQPMprojects completed with a medium risk and high risk associated with themand the total number of incomplete projects. In one embodiment, thereport also includes a table indicative of the gateway conformancescores for the total number of APQP projects categorized with respect tothe A, B, C, and D category of risk.

Further, the display module 302 may enable the team member to view theassociated PQPM projects, as illustrated in FIG. 35. For example, if theteam member clicks on the AB bar on the chart, the display module 302may display all the APQP projects falling under the AB risk category, ina table as illustrated in FIG. 35. As will be appreciated by a personhaving ordinary skill in the art, the display module 302 may create ahyperlink in the bar charts to link to a table illustrating theinformation associated with the PQPM projects associated with thecategory of the bar.

The developing module 306 may develop an NPI program view report, tofacilitate the team member to view all the PQPM projects within an NPIprogram and corresponding gateway conformance scores for each PQPMproject. In one embodiment, the display module 302 may be configured toprovide a path to the team member through the user interface window 3300to get the NPI program view report. For example, the user interfacewindow 3300 may include an

“NPI project View” tab, as illustrated in FIG. 36, to enable thereceiving module 304 to receive NPI program ID as a search term from theteam member. Subsequently, the team member may click on a “Get Report”tab to view all the PQPM projects and the corresponding gatewayconformance scores for the NPI project.

Further, the display module 302 may be configured to display a userinterface window 3700 including the “PQPM NPI part summary report”, asillustrated in FIG. 37. As illustrated in the user interface window 3700the NPI program view report is formed in a tabular form. In oneembodiment, the report may include PQPM projects for parts within theNPI program. As will be understood by a person ordinarily skilled in theart, the NPI program is executed for a product that includes a pluralityof parts. Further, the PQPM project is executed for a single part of theproduct. Therefore, a single NPI program may include multiple PQPMprojects. In one embodiment, the report may include the PQPM project ID,the part name and part number for which the PQPM project is executed,the NPI id of the associated NPI program, PQPM project title, teamleader for the PQPM project, corresponding supplier name and code, alongwith the corresponding gateway status. For example, the first row of thetable in the report, may indicate a PQPM project 1. For the PQPM project1, the gateway status may be based on the gateway conformance score,associated with the PQPM project 1. In a further embodiment, the displaymodule 302 may provide a path for the team member to view the details ofevery PQPM project in the report by clicking on desired PQPM project.Subsequently, as the team member clicks on the PQPM project within thereport, the display module 302 may display the “Summary” tab of theselected PQPM project.

In an embodiment, the developing module 306 may provide a path to theteam member through a user interface window 3300 to develop a PQPM riskreport as illustrated in FIG. 38. The PQPM risk report may indicate allthe sub-activities that are at a risk for a given NPI program. As willbe understood by a person skilled in the art, the sub-activities may beexecuted for more than one PQPM projects within the NPI program. In oneembodiment, the user interface window 3300 may include a “PQPM riskreport” tab. Subsequently, the receiving module 304 may receive textualinput from the team member for searching an NPI program by the NPIprogram id. Further, the team member may click on the “Get report” tabto subsequently enable the development module 306 to generate a PQPMrisk report in a user interface window 3900, as shown in FIG. 39.

In an embodiment, the PQPM risk report, as illustrated in FIG. 39 mayinclude the sub-activities that may have a gateway indicator indicatinga red and/or yellow color. In an alternate embodiment, the report mayinclude the sub-activities having gateway indicators indicating a firsthatch pattern and/or a second hatch pattern. As explained previously,the red color or the first hatch pattern of the gateway indicatorindicates a high risk associated with the sub-activity. The yellow coloror the second hatch pattern of the gateway indicator indicates a mediumrisk associated with the corresponding sub-activity.

In an embodiment, the report may include the PQPM project id associatedwith the sub-activity at risk. In addition, the report includes the partname, part number associated with the PQPM project, project title,supplier name and code, the description of the sub-activity at risk,description of the corresponding activity, and the correspondingrelevant gateway associated with the sub-activity at risk. For example,if a sub-activity associated with gateway 3 is at risk, then the reportmay include only that sub-activity and the associated gateway 3 with thecorresponding differentiator, such as red or yellow color, and/or firstor second hatch pattern respectively. In one embodiment, the reportenables the team member, and/or the team leader to monitor riskmitigation activities for the NPI program. Further, the display module302 may enable the team member to view the details associated with thesub-activity and the PQPM project listed in the report by clicking onthe desired project. In one embodiment, the PQPM project listed in thereport may include a hyperlink to the “Details” tab of the correspondingproject and the sub-activity.

In an embodiment, the developing module 306 may provide a path to theteam member on a user interface window 3300 to develop a PQPM NPIGateway conformance Report, as illustrated in FIG. 40. The PQPM NPIGateway conformance Report may indicate all the PQPM projects and thesub-activities associated with a NPI program for a plurality of userdefined fields, such as gateway, component type etc. In one embodiment,the display module 302 may be configured to display a “PQPM NPI gatewayconformance report” tab, on the user interface window 3300. In oneembodiment, PQPM NPI gateway conformance report” tab may facilitate thereceiving module 304 to receive textual inputs from the team member forgenerating the PQPM NPI gateway conformance report. In one embodiment,the textual inputs may include one or more fields for restricting thereport, such as a project type, NPI program id, gateway, part number,PQPM project ids, team member, supplier code etc. Subsequently, the teammember may select the data columns desired to be viewed in the report.For example, the display module 302 may provide a path on a userinterface 4100, as shown in FIG. 41, to the team member for selectingthe data columns to be viewed in the report.

In an embodiment, the developing module 306 may generate the PQPM NPIgateway conformance report based on the received inputs from the teammember, as shown in FIG. 42. For example, for the input fields NPIprogram id, gateway selected as gateway 6, and project type selected asa component project type, the developing module 306 may generate thereport based on only the entered fields. Therefore, the report, on auser interface window 4200 may include all the PQPM projects ofcomponents type under the NPI program id along with the status of allsub-activities associated with the gateway 6 for all the PQPM projects.In one embodiment, the PQPM NPI gateway conformance report mayfacilitate the team member in tracking the execution status of all thesub-activities associated with all the PQPM projects within an NPIprogram. Also, the report enables the team member to track thesub-activities associated with one or more gateways.

The present disclosure (i.e., Graphic User Module 110, any part(s) orfunction(s) thereof) may be implemented using hardware, software or acombination thereof, and may be implemented in one or more computersystems or other processing systems. However, the manipulationsperformed by the present disclosure were often referred to in terms,such as comparing or checking, which are commonly associated with mentaloperations performed by a human operator. No such capability of a humanoperator is necessary, or desirable in most cases, in any of theoperations described herein, which form a part of the system. Rather,the operations are machine operations. Useful machines for performingthe operations in the system may include general-purpose digitalcomputers or similar devices.

In an embodiment of the present disclosure, the present system isdirected towards one or more computer systems capable of carrying outthe functionality described herein.

The computer system 4300 includes at least one processor, such as aprocessor 4302. The processor 4302 is connected to a communicationinfrastructure 4304, for example, a communications bus, a cross overbar, a communication network, and the like. Various software embodimentsare described in terms of this exemplary computer system 4300. Afterreading this description, it will become apparent to a person skilled inthe relevant art(s) how to implement the system using other computersystems and/or architectures.

The computer system 4300 includes a display interface 4306 that forwardsgraphics, text, and other data from the communication infrastructure4304 for display on a display unit 4308.

The computer system 4300 further includes a main memory 4310, such asrandom access memory (RAM), and may also include a secondary memory4312. The secondary memory 4312 may further include, for example, a harddisk drive 4314 and/or a removable storage drive 4316, representing afloppy disk drive, a magnetic tape drive, an optical disk drive, etc.The removable storage drive 4316 reads from and/or writes to a removablestorage unit 4318 in a well-known manner. The removable storage unit4318 may represent a floppy disk, magnetic tape or an optical disk, andmay be read by and written to by the removable storage drive 4316. Aswill be appreciated, the removable storage unit 4318 includes a computerusable storage medium having stored therein, computer software and/ordata.

In accordance with various embodiments of the system, the secondarymemory 4312 may include other similar devices for allowing computerprograms or other instructions to be loaded into the computer system4300. Such devices may include, for example, a removable storage unit4320, and an interface 4322. Examples of such may include a programcartridge and cartridge interface (such as that found in video gamedevices), a removable memory chip (such as an erasable programmable readonly memory (EPROM), or programmable read only memory (PROM)) andassociated socket, and other removable storage units 4320 and interfaces4322, which allow software and data to be transferred from the removablestorage unit 4320 to the computer system 4300.

The computer system 4300 may further include a communication interface4324. The communication interface 4324 allows software and data to betransferred between the computer system 4300 and external devices.Examples of the communication interface 4324 include, but may not belimited to a modem, a communication network interface (such as anEthernet card), a communications port, a Personal Computer Memory CardInternational Association (PCMCIA) slot and card, and the like. Softwareand data transferred via the communication interface 4324 are in theform of a plurality of signals, hereinafter referred to as signals 4326,which may be electronic, electromagnetic, optical or other signalscapable of being received by the communication interface 4324. Thesignals 4326 are provided to the communication interface 4324 via acommunication path (e.g., channel) 4328. The communication path 4328carries the signals 4326 and may be implemented using wire or cable,fiber optics, a telephone line, a cellular link, a radio frequency (RF)link and other communication channels.

In this document, the terms “computer program medium” and “computerusable medium” are used to generally refer to media such as theremovable storage drive 4316, a hard disk installed in hard disk drive4314, the signals 4326, and the like. These computer program productsprovide software to the computer system 4300. The disclosure is directedto such computer program products.

Computer programs (also referred to as computer control logic) arestored in the main memory 4310 and/or the secondary memory 4312.Computer programs may also be received via the communication interface4304. Such computer programs, when executed, enable the computer system4300 to perform the features of the present disclosure, as discussedherein. In particular, the computer programs, when executed, enable theprocessor 4302 to perform the features of the present disclosure.Accordingly, such computer programs represent controllers of thecomputer system 4300.

In accordance with an embodiment, where the system is implemented usinga software, the software may be stored in a computer program product andloaded into the computer system 4300 using the removable storage drive4316, the hard disk drive 4314 or the communication interface 4324. Thecontrol logic (software), when executed by the processor 4302, causesthe processor 4302 to perform the functions of the system as describedherein.

In another embodiment, the system may be implemented primarily inhardware using, for example, hardware components such as applicationspecific integrated circuits (ASIC). Implementation of the hardwarestate machine so as to perform the functions described herein will beapparent to persons skilled in the relevant art(s). In yet anotherembodiment, the system is implemented using a combination of both thehardware and the software.

Industrial Applicability

Generally, organizations utilize various Product Quality Planning andManagement (PQPM) process to ensure that new parts meet the qualitystandards needed for New Product Introduction (NPI) programs. However,the way the organization manages the PQPM process is very inefficient,where the team members utilize various forms of spreadsheets tocollaborate and track PQPM progress with internal partners as well asexternal suppliers. This project provides a significant opportunity tostandardize how PQPM process is organized and executed in organizations.This project will ensure that there is a tool available to promotecollaboration and enable teams to execute the PQPM process efficiently.The user interface 112 provides a collaborative environment for trackingthe execution status of the activities of the PQPM processes throughoutthe organization. The user interface 112 further enables the teammembers to track the progress of the PQPM project efficiently and thus,saving time and cost and at the same time maintaining the quality of theproducts. Further, the user interface 112 enables to standardize thevarious activities that need to be executed during the productdevelopment cycle.

In an embodiment, the PQPM projects and the associated activities may belinked to various New Product Introduction (NPI) programs, which enablesthe team members and the organizations to monitor a risk associated atthe product level as well as at the component level. The team membersmay simultaneously take necessary steps, based on the monitored risk, toperform risk mitigation for the PQPM projects associated with the NPIprograms.

In an embodiment, the user interface 112 provides a solution to the teammembers to track the progress of PQPM project during the productdevelopment cycle. As illustrated in FIG. 44, process 4400 details outthe steps of facilitating the PQPM project.

At step 4410, the GUI module 110 displays various activities that needto be executed by the team members for a successful completion of thePQPM project. These activities include the organization standardactivities or industry standard activities that need to be executedbefore a successful launch of the part is done.

At step 4420, the GUI module 110 receives textual inputs for measurementcriterion that are indicative of an execution status of the activitiesand the corresponding sub-activities. In an embodiment, thesub-activities has an associated expectation based on which themeasurement criterion is defined for the sub-activities. Further, thesub-activities have an associated gateway based on a phase of executionof each of the sub-activities. The phase of execution includes conceptdefine phase, concept measure phase, concept explore phase, developdesign phase, develop verify phase and pilot phase. Further, the userinterface 112 may receive the measurement criterion based on aforecasted execution and assessment of reaching an expectationassociated with the sub-activities corresponding to each of theactivities. In an embodiment, the measurement criterion for theforecasted execution is based on first pre-determined scoring rates. Thefirst pre-determined scoring rates is based on a probability of meetinga specified target date, a specified quality level and a costexpectation associated with the one or more sub-activities. Further, theuser interface 112 receives the measurement criterion for the assessmentif the forecasted execution is scored as completed. The computerimplemented method of claim 23, wherein the measurement criterion forthe assessment is based on second pre-determined scoring rates. The userinterface 112 visually represents the measurement criterion as gatewayindicator. The gateway indicator is based on one of first pre-determinedscoring rates associated with the forecasted execution and secondpre-determined scoring rates associated with the assessment. In anembodiment, the visual representation in the gateway indicator is atleast one of a color based indicator, a number based indicator, a letterbased indicator, a hatch pattern based indicator, an alphanumeric basedindicator.

The user interface 112 further enables to link the activities,associated with the PQPM project, with a parent PQPM project.Subsequently, the user interface 112 automatically receives themeasurement criterion for the linked activities from the parent PQPMproject.

At step 4430, the team members may track the progress of the PQPMproject based on the measurement criterion indicative of the executionstatus of the activities. In an embodiment, the user interface 112displays a real time summary of the PQPM project. The real time summaryincludes the gateway indicator for the sub-activities corresponding tothe one or more activities. The gateway indicator provides an indicationof the execution status of the sub-activities and thus, the progress ofthe activities. Basically, the gateway indicator provides an indicationof the execution status of the activities based on the associatedgateway indicators of the corresponding sub-activities. In anembodiment, the gateway indicator provides an indication of the riskassociated with the one or more sub-activities. Further, the userinterface 112 enables the team members to track the progress based onscoring at the different gateways associated with the activities and thecorresponding sub-activities. The real time summary includes the scoringparameter to track the progress of the PQPM project. The scoringparameter is based on a gateway indicator corresponding to one or moresub-activities associated with the one or more activities.

At an independent step 4440, the user interface 112 may develop reportsto monitor a risk associated with the PQPM project, the report is basedon the measurement criterion associated with the execution status of theone or more activities. In an embodiment, as the PQPM projects may berolled up to the NPI programs, the user interface 112 may enable theteam members to monitor the risk both at the component level and at theproduct level. The user interface 112 may provide various reports suchas a NPI project report, PQPM risk report, PQPM NPI gateway conformancereport and NPI program view report.

The NPI project report displays a risk and gateway conformance scoresassociated with the PQPM projects in the NPI program. The NPI projectreport further displays a risk status for the parts associated with thevarious PQPM projects in the NPI program. The NPI program view reportdisplays gateway conformance scores associated with the PQPM projects inan NPI program. The NPI program view report further displays informationassociated with the PQPM projects in the NPI program. The PQPM riskreport displays a risk associated with sub-activities, associated withthe activities, for an NPI program. The PQPM risk report displays themeasurement criterion associated with the sub-activities associated withthe activities. The PQPM NPI gateway conformance report displays gatewayindicators associated with the activities. The user interface furtherenables the team members to export the summary and the reports in XMLformat.

While aspects of the present disclosure have been particularly shown anddescribed with reference to the embodiments above, it will be understoodby those skilled in the art that various additional embodiments may becontemplated by the modification of the disclosed machines, systems andmethods without departing from the spirit and scope of what isdisclosed. Such embodiments should be understood to fall within thescope of the present disclosure as determined based upon the claims andany equivalents thereof.

1. A computer-implemented method to facilitate a Product QualityPlanning and Management (PQPM) project associated with a productdevelopment cycle, the method comprising: displaying on a user interfaceone or more activities to be executed for the PQPM project; receiving,with an aid of the user interface, textual inputs indicative of ameasurement criterion associated with an execution status the one ormore activities; and developing a report to monitor a risk associatedwith the PQPM project, the report is based on the measurement criterionassociated with the execution status of the one or more activities. 2.The computer implemented method of claim 1, wherein the one or moreactivities include: a. requirements management; b. quality history; c.design Failure Mode and Effects Analysis (FMEA); d. drawings andspecifications; e. design verification plan and report; f. design andmanufacturing reviews; g. team feasibility and management commitment; h.special characteristics; i. facilities, tools and gauges; j. prototypebuild control plan; k. prototype build; l. manufacturing processflowchart; m. process FMEA; n. pre-launch control plan; o. operatorprocess instructions; p. packaging specifications; q. measurementsystems analysis; r. production trial run; s. preliminary processcapability study; t. production control plan; u. production validationtesting; v. external supplier Production Part Approval Process (PPAP);and w. PPAP status.
 3. The computer implemented method of claim 2,wherein each of the one or more activities includes one or moresub-activities.
 4. The computer implemented method of claim 3, whereineach of the one or more sub-activities has an associated expectationbased on which the measurement criterion is defined for each of the oneor more sub-activities.
 5. The computer implemented method of claim 3,wherein each of the one or more sub-activities has an associated gatewaybased on a phase of execution of each of the one or more sub-activities.6. The computer implemented method of claim 1 further comprisingproviding a path on the user interface to associate at least one NewProduct Introduction (NPI) program with the PQPM project.
 7. Thecomputer implemented method of claim 6, wherein the NPI program includesone or more PQPM project created for various parts during the productdevelopment cycle.
 8. The computer implemented method of claim 1 furtherincludes visually representing the measurement criterion as a gatewayindicator.
 9. The computer implemented method of claim 8, wherein thegateway indicator is based at least on one of first pre-determinedscoring rates associated with a forecasted execution of the activitiesand second pre-determined scoring rates associated with an assessment ofthe activities.
 10. The computer implemented method of claim 1, whereindeveloping the report includes developing a New Product Introduction(NPI) project report, PQPM risk report, PQPM NPI gateway conformancereport and NPI program view report.
 11. The computer implemented methodof claim 10, wherein the NPI project report displays a risk and gatewayconformance scores associated with the PQPM projects in an NPI program.12. The computer implemented method of claim 11, where in the NPIproject report displays a risk status for the parts associated with thePQPM projects.
 13. The computer implemented method of claim 10, whereinthe NPI program view report displays gateway conformance scoresassociated with the PQPM projects in an NPI program.
 14. The computerimplemented method of claim 13, wherein the NPI program view reportdisplays information associated with the PQPM projects in the NPIprogram.
 15. The computer implemented method of claim 10, wherein thePQPM risk report displays a risk associated with sub-activities and theactivities, for an NPI program.
 16. The computer implemented method ofclaim 15, wherein the PQPM risk report displays the measurementcriterion associated with the sub-activities associated with theactivities.
 17. The computer implemented method of claim 10, wherein thePQPM NPI gateway conformance report displays gateway indicatorsassociated with the one or more activities.
 18. The computer implementedmethod of claim 1, wherein the user interface is configured to provide apath to export the reports in XML format.
 19. A system comprising: aprocessor for facilitating a Product Quality Planning and Management(PQPM) project associated with a product development cycle, a tangible,non-transitory memory configured to communicate with the processor, thetangible, non-transitory memory having instructions stored thereon that,in response to execution by the processor, cause the processor toperform operations comprising: displaying on a user interface one ormore requirements to be executed for the PQPM project; receiving, withan aid of the user interface, textual inputs indicative of a measurementcriterion associated with an execution status of the one or moreactivities; and developing a report to monitor a risk associated withthe PQPM project, the report is based on the measurement criterionassociated with the execution status of the one or more activities. 20.An article of manufacture including a non-transitory, tangible computerreadable medium having instructions stored thereon that, in response toexecution by a computer-based system for facilitating a Product QualityPlanning and Management (PQPM) project associated with a productdevelopment cycle, cause the computer-based system to perform operationscomprising: displaying on a user interface one or more activities to beexecuted for the PQPM project; receiving, with an aid of the userinterface, textual inputs indicative of a measurement criterionassociated with an execution status of the one or more activities; anddeveloping a report to monitor a risk associated with the PQPM project,the report is based on the measurement criterion associated with theexecution status of the one or more activities.